DESIGN DATA

ION AND MAINTENANCE SCHEDULE

ERVATION OF BOILER
 INTRODUCTION

2; MIS. LSIL make FBC Boiler Mechanical design & detailed engineering was canied

out by Ms. UNIPRODUIRE ENGINEERING (P) LTD., TRICHY based on

MIS. ERK GMBH - BERLIN performance engineering.

2; Boiler is of a special type which is generally called by ERK as "CORNER TUBE

SINGLE DRUM BOILER".

2; Entire boiler including steam drum will be supported in the down comers & water

wall bottom headers by providing "Resting sliding support" between boiler & boiler

supporting structures.

> This single drum Boiler is designed with stable frame work of unheated down comers

and headers on Rectangular plan welded to gas tight walls of pipes to f o m a closed

tubular cage. The cage including all welded and supported heating surfaces; is self

supporting with comer Down comers which will be rested on the boiler supporting

slmcture at an elevation of 6050 mm.

2; Since the Boiler is designed for high ash fuel, open Bottom type design is provided
along with Sporger air header to facilitate the Bed Ash draining through the Bottom of
the Hopper.
 BOILER DESIGN DATA
BOILER l T P E SINGLE DRUM WATER TUBE BOILER (FBC)
CAPACITY 90 TPH

MAX WORKING PRESSURE SO kg/cm2 (g)

SUPER HEATER OUTLET
69 kg/cm2 (g)
PRESSURE
SUPER HEATER OUTLET
TEMPERATURE 49@+ 5OC

FURNACE
TYPE OF FIRING FLUIDISED BED COMBUSTION (UNDERBED)
BED SIZE 9400 mm X 4900 mm
SECOND PASS SIZE 2900 mm X 10000 mm
FUEL FIRING

FUEL -I 100% UKHNI COAL

-

55% UKHNI COAL

10% REJECT COAL
FUEL -11
25% CHAR
10% COAL SLURRY

HEATING SURFACE AREA (Mz)

ECONOMISER ASSY- I 1123.00
ECONOMISER ASSY- I1 1123.00
WATER WALL ASSY.(BED COIL AND EVAPORATOR COIL) 1490.00
PRIMARY SUPERHEATER ASSY 509.00
SECONDARY SUPERHEATER ASSY. 516.00

B16 5 1500#/150#
I
dWOJ 03880d 3 A l V A OSI
 MATERIAL DESIGN DE3IGN
TYPE
OPERATION SPECATION PR.Ksrg TEMP. OC

GATE I5 SCR HANDWHEEL N 1 I50 I S 0 VALVE FORPA FAN MLET DRAUGMTESTPOCKFT.

Y
GATE 15 SCR HANDWHEEL N I 150 ISO VALVE FORPA FAN-I O ~ ~ D M U O H T T E SWCKFT.
T

GATE 15 - SCR I HANDWHEEL N I I I50 I S 0 VALVE FOR PA FAN-I1 OUI'LETDRAUGHIEST POCKET.

GATE I5 SCR HANDWHEEL N I 150 I S 0 VALVE FORCOMPARTMEmDRAUGMTFSTPOCKFT.

-
GATE I5 SCR HANDWHEEL N I 150 I S 0 VALVE FOR COMPARTMENTDRAUGMI€iT POCKFT.

GATE IS I - SCR I HANDWHEEL I N I I 150 I S 0 VALVE FORBED PRESSURE GAUGE

1.12 GLV-IIl3BiGLV-I114 GLOBE 25 800 SW HANDWHEEL Y 2 SAlOS 80 195 ROOT& I S 0 VALVES FOR AIRVENT AT SATURATED STEAM LINE

1.13 GLV-IIl5&GLV-1126 GLOBE 25 800 SW HANDWHEEL Y 2 %I05 83 124 ROOTBISO VALVES FOR ECONOMISERTO DRUM AT FEED LINE AIR VENT

1.14 GLV-1117BiGLV.1128 GLOBE 25 800 SW HANDWHEEL Y 2 SAlOS 80 295 ROW 6 ISO VAL-S FOR SAMPLE COOLERSATURATED STEAMLINE

1.15 GLV-IIBBiOLV-I130 GLOBE 25 800 SW HANDWHEEL Y 2 SAlO5 80 295 ROOTBiISO VALVES FOR SUPER HEATER.! MLETHEADER DRAIN
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LEVEL DETAIL FOR STEAM DRUM
APPLICATION

Drag Chain Feeder

415V, 3 Phase, 50
or Feed Control Valve-

Motorised Bypass Valve

415V, 3 Phase, 50
For Feed Control Valve-
 APPLICATION

CV Isolation At
LUBRICATION SCHEDULE
I

UTILITY SPECIFICATIONS & REQUIREMENT

I

1 AUXILIARY COOLING WATER

I INSTRUMENT AIR

I CHEMICALS

I
BED MATERIAL. CHARCOAL & KEROSENE
AXILIARY COOLING WATER AND COMPRESSED AIR REQUIREMENT
AUXILIARY COOLING WATER REQUIREMENT:

SI.
APPLICATION QUANTITY
No.
01. SAMPLE COOLER 5362 LPH.

COOLING WATER PRESSURE : 2.0 TO 4.0 Kg I cmZ(g)

TEMPERATURE : 32" C

COOLING WATER CAN BE USED FROM SERVlCE WATER. THE

CHLORIDE CONTENT IN THIS WATER MUST BE LESS THAN 35 ppm.

COMPRESSED AIR REQUIREMENT:

TOTAL AIR
APPLICATION

MARGIN (70%) .34.44 m3/hr@7~scg

TOTAL REQUIREMENT. 84 m3/hr @ 7 kscg

PRESSURE : 7.0 ~ ~ / c m ~ ( g )
OIL FREE : 1 PPM
DEW POINT : < -20" C

NOTE: THE COMPRESSED AIR REQUlREMENT GIVEN ONLY FOR BOlLER

PNEUMATIC INSTRUMENTS.
 CHEMICAL REQUIREMENT & SPECIFICATION
FOR HP DOSING SYSTEM
NAME TRI-SODIUM PHOSPHATE
FORMULAE Na3P04
COLOR & CRYSTALLINE FORM WHITE, POWDER
SPECIFIC GRAVITY AT 17 5'C 2 537
SOLUBILITY IN 100 PARTS
OF COLD WATER O'C 45
OF HOT WATER 1 0 0 ' ~ 77
MIN QUANTITY TO BE STOCKED 75 Kgs / MONTH
.
(TRI-SODIUM PHOSPHATE SHOULD BE DILUTED TO 1% CONCENTRATION)
FOR ALKALI BOILOUT
TRI-SODIUM
NAME SODIUM CARBONATE
PHOSPHATE
FORMULAE Na3P04 NazC03
COLOR & CRYSTALLINE FORM WHITE, POWDER WHITE, POWDER
SPECIFIC GRAVlTY AT 17 5°C 2 537 2 533
SOLUBILITY IN 100 PARTS
OF COLD WATER 0°C 45 7 1
OF HOTWATER 100°C 77 48 5
-

QUANTITY 260 KgslSOILOUT 260 KgslSOILOUT

NO OF BOILOUT 3 3
NOTE
THE ABOVE QUANTITY IS TENTATIVE ONLY AND THE SAME SHOULD BE CHECKED
AND ADJUSTED DURING BOILER OPERATION
IN THE ABOVE QUANTITY INITIAL FILLING IS NOT CONSIDERED, REQUIREMENT FOR
THE SAME IS AS FOLLOWS
1) TRI-SODIUM PHOSPHATE - 3 Kgs
 BED MATERIAL, CHARCOAL, KEROSENE & OIL REQUIREMENT

) BED MATERIAL REQUIREMENT:

~~ ~
Quantity of Bed material for initial startup 151800 Kgs.
1
.. Quantity of Bed material for further 10 Startups 152000 Kgs.

Total quantity bed material to he stocked 303800 Kgs.

BED MATERIAL SPECIFICATION:

Maximum particle size 2.36 mm
Particles to pass through sieve No. 8
Minimum particle size 0.85 mm
Particles to stay on sieve No. 20
Particles density 2000 ~ g i m ~
Bulk density 1000 to 1100 ~ g l r n ~
Chemical composition
Alumina 45% to 35%
Silica 55% to 65%
Fusion temperature 1400°C(Min.)
(Bed material shall be from Crushed refractory bricks or from sieved ash).
I
CHARCOAL REQUIREMENT:
1
Quantity of charcoal per startup 300 Kgs.
i
Quantity of charcoal to he stocked 3000 Kgs. (For 10 Startups)

CHARCOAL SPECIFICATION:
Charcoal size 15 to 25 mm LUMPS
.I
Calorific value 6600 KcalIKg.
. ~)
(Charcoal should be sun dried)
r
.) KEROSENE:
Quantity of kerosene per startup 33 Litres.
j
Quantity of kerosene to he stocked 330 Liters. (For 10 Startups)
J
! OIL:
Quantity of Oil per startup 40 Liters / hr
Quantity of Oil to he stocked 400 Liters. (For 10 Startups)
 BOILER SYSTEM DESIGN DESCRIPTON
This fluidised'bed combustion boiler designed for maximum continuous rating of 90,000 kg/hr
having pressure of 69 kg/cm2(g) at main steam stop valve of boiler with a steam outlet temperature
of 490 *5'C by fixing with the following fuels.

01. 100% Ukhni Coal - 90 TPH

02. Fuel combination consists of

%,
10% Reject coal
1 - 90TPH

25% Char

10% coal slurry. J

The boiler is designed with super heater temperature control range from 60% to 100% MCR.

This boiler is called corner tube single drum boiler with natural circulation. Entire boiler including
steam drum will be supported in the down comer and water wall bottom header by providing. The
Resting sliding support behveen boiler and boiler supporting structure. The boiler consisting of
steam drum, membrane water wall panels; bed coils, evaporator, primary super heater, secondary
super heater, Tertiary super heater, Economiser, Air heater, boiler Inter connecting piping, air and
g,as ducting, fuel feeding system supporting structure with roof and side cladding, platforms and
staircases etc. It also consists of the other equipments like bunker, fans, ESP, HP dosing systems,
blow down tanks, start up oil firing are also supplied along with boiler.

,> The deaerator, LP dosing system and feed pumps are already exist.
i
THE STEAM AND WATER SYSTEM

GENERAL

WATERWALL & BOILER CAGE

GENERAL
OPERATION
BLOW DOWN
ASH DEPOSITS
MAINTENANCE
TUBE REPAIRS
DATA SHEET

STEAM DRUM

GENERAL
DRUM INTERNALS
INSTALLATION
DATA SHEET

ECONOMISER

GENERAL
FEED WATER CONTROL
MAINTANANCE
DATA SHEET
THE STEAM AND WATER SYSTEM

GENERAL

All the water required to produce steam is supplied by the Existing boiler feed water pumps. The
feed water passes through the Economiser adds only sensible heat to the feed water.

From the drum, water is circulated through the natural circulation circuit. This circuit add latent heat
to the water and thus this circuit; may be termed as evaporate circuit. As the steam and water mixture
enters the drum from this circuit, the drum intemals, separate the stearq from the mixture. The
separated water along with the incoming feed water is continuously circulated through thls circuit.

The natural circulation circuit is formed by the drum down comers, bed evaporator, water walls,
roof tubes, rear pass evaporator, water wall outlet headers and riser pipes.

The saturated steam from the drum is superheated in the super heater coils, in thr.ee stages. The steam
passes through the connecting links, primary super heater inlet header; primary super heater coils,
primary super heater outlet header, connecting link between primary super heater outlet and
secondary super heater inlet header, secondary super heater inlet header, secondary super heater
coils, secondary super heater outlet header, connecting link between secondary super heater outlet
header and De-super heater, De-super heater, connecting link between De-super heater and tertiary
super heater, inlet header, tertiary super heater coils, tertiary super heater outlet header.

De-super heater is located in between secondary outlet and tertiary super heater inlet, it serves to
control the boiler outlet steam temperature.
 WATER WALL & BOILER CAGE

GENERAL

The water wall consists of Front wall, Division wall, Rear wall, Left and Right sidewall panels and
roofs are formed by the tubes rising from the front and rear wall panels. Also the water wall is
divided with two chambers by the division water wall panels in between the front and rear water wall
panels. Front wall and Division wall are provided with bed evaporator coils in first chamber and
Rear wall provided with evaporator coils in second chamber. The water wall are connected with
boiler cage which is formed by the two main down comer from the steam drum along with unheated
Down comers and Raisers from water wall headers.

The water from drum flows through two main down comer to the bottom furnace Front wall,
Division wall, side walls and rear wall header. From this bottom front and division wall headers
water flows through the bed evaporator tubes and then to the upper water wall panels. Similarly from
the rear wall bottom header water flows through the evaporator coils and then to the rear upper
panels.

The bed evaporator is completely immersed within the fluidized bed. The bed evaporator is provided
to extract heat from fluidized bed and to keep the bed temperature well below the ash fusion
temperature.

I The water wall is made of fin welded tube panels

The front wall consists of tubes that rise from the bottom bed evaporator coils and end in the front
roof panels and front roof panels end in the top front roof header.

The rear wall panels through evaporator coils are formed by the tubes that originates from the rear
bottom headers and rise up to the rear roof tubes and rear roof tubes end in the top rear roof header.

The division wall panel is formed by the tubes that originates from the division wall headers and rise
from the bed evaporator coils and end up to the division wall top header and the same is connected to
rear roof top header by riser connecting piping to facilitate the flue gas to enter in second pass
chamber.
The two side walls are formed from the tubes that rise from the bottom side wall headers and they
are crowned by the two side wall outlet header.

Front wall roof header & rear wall roof header are connected with both the side wall headers. From
the side wall top headers there is only one riser pipe from each header to carry the steam water
mixture to the drum. From the roof top headers there are 8 riser pipes to carry the steam water
mixture to the drum.

The water walls are provided with openings and seal boxes for the coil bends of, bed material feed
chutes, view ports, man hole doors, soot blowers opening (future) etc. To protect the boiler from the
effect of explosions buck stays are used. They are nothing but beams attached to the water wall
tubes. The buck stay beams are welded at the one end with down comer and other end made as
sliding connections between water wall and down comer gap. These beams prevent the furnace from
blowing inward or outward in the case of furnace puffs o r increased negative pressure.

Water walls serve two h c t i o n s mainly. They form a gas tight enclosure to contain the hot flue
gases. They form the evaporator circuit which generates steam. Natural circulation is established
by the density difference between the water in down comers and water - steam mixtures in water
walls. The rate of the circulation adjusts itself until an equilibrium is reached such that the
difference between the hydrostatic head at the feet of down comers and the water walls is equal to
the sum of pressure drops due to friction and acceleration- of the flow medium in the circuit.
Circulation will be high at lower pressure and at lower loads. Circulation will be reduced when
feed water temperature increases and when drum level is low.

OPERATION
INTERNAL DEPOSIT
Sincethe design heat transfer rates in water cooled furnaces are normally high, it is essential that the
tubes be kept free from scale formation and copper and iron oxides deposits. This i s accomplished
by proper boiler water and feed water treatment.

Scale formation i s the deposition of an insulating film on the water side of the tube wall, which
raises the hot face temperature and may result in overheating of the tube section. Boiler water
treatment aims to eliminate deposition of scale forming components by substituting non-scale
forming components.
BLOW DOWN

Boiler blow down is used as a means of controlling boiler water concentrations (solids and
alkalinity) and to remove sludge formation. The frequency of blowing down depends upon local
conditions, such as; characteristic of the water, nature of feed water treatment and rating of the
boiler, etc. In this boiler the continuous blow down system is sufficient.

ASH DEPOSITS

The fluidized bed is operated at a temperature which is 850°C to 950°C less than the deformation
temperature of ash. Hence ash fusion and slagging problems are eliminated.

MAINTENANCE

Routine inspections of furnace wall tubes, drum and headers should be made after breakage and
during annual outages. During this, drum should be opened and hand hole should be removed from
headers. The condition of the drum intemals should be clean and intemal'surfaces should be
inspected for deposits. Any deposits should be removed and headers drum and tubes flushed out with
water. Furnace tubes should be externally for blistering, corrosion, erosion and cracking. For this
purpose fire sides of all exposed furnace tubes must first be thoroughly cleaned of ash deposition and
manhole doors should be properly closed before firing the boiler.

TUBE REPAIRS

A tube section, which has failed, or which must be replaced because of danger of can in most cases
ekily be replaced. After removing the furnace wall insulation behind failed area, the tube section is
removed by cutting across the tube, sufficiently above and below the failure and carefully cutting the
web along side the tubes (See note.). The inserting and rewelding a new tube section, the tube ends
should be properly prepared for welding.

NOTE:

The longitudinal cuts must extend beyond the perpendicular cuts sufficiently to welding completely
around the periphery of the tube when installing the new section. Webs between tubes must be
replaced and made gas tight.
It must be recognized that it is impossible t o include repair procedure (methods, welding,
techniques, etc) to cover all pressure parts and associated structural components of steam generator.
It is recommended that all repairs should be done by competent and qualified personnel and all
welding should be accordance with the .recommended rules for repairs of boilers.
STEAM DRUM

GENERAL

The steam drum is of fusion welded type, and fitted with high efficiency intemals. The steam drum
provided with 2 nos manhole door to open inwards. The following nozzles are provided in the steam
drum.

,-\

The thickness of the drum is amved based on the requirements as specified under IBR 1950 with
latest amendments.
DRUM INTERNALS

The boiler dmh forms a part of the circulation system of the boiler. It's main functions are

a) Providing the necessary space for separation of steam from mixture of steam and water.

b) Housing the equipment needed for purification of steam.

C) Meeting the steam demand fluctuation by its steam storage capacity

The drum intemals combine simplicity and efficiency to produce low maintenance cost and high
steam quality.

The drum is positioned horizontally in front of the boiler. It is supported by the down comer which is
rested on the boiler structure. The steam-water mixture, entering the drum from side water wall top
headers and roof panel top headers, is collected in the separating chamber formed by the vertical
baffle panels. The primary separation of steam and water takes place in the separating chamber. Of
the water drops down after impact and mix with the incoming feed water. A portion of the water is
drained off through the perforated continuous blow down pipes at this point of high solids
concentration. The blow down line is provided with an motor operated blow down with isolation
valve. The steam and some water is released over the top ends of the panel and cascades into the top
p,art of the drum. Here the wet steam rises and passes through the drier screens. The water, as it
undergoes the tortuous path provided by the screens, gets collected and this water is drained to the
waterside of the drum. Dry steam leaves the drum through the top one number steam outlet nozzles.

Drum safety valves are set to open when the drum gets pressurized above limits. Drum level is
sensed to control the feed water flow. Drum level is indicated by the local drum water level gauge
and by the water level indicator. The motorized operated emergency drain (Intermittent blow down)
with isolation valves is to be used when the drum level shoots up abnormally.
 1 INSTALLATION
The following inshuctions are to be adhered to for the proper functioning of drum

1
1. Study the drum intemal drawing and learn the purpose of the various intemal parts.
i

2. To prevent moisture from bypassing the screen drier and mixing with dry steam as it leaves
' ) the drum, all the joints in the drier assemblies must be absolutely tight.

Seal welding, where indicated on the drawing, must be carefully done. All bolts are to have
1
two washers, one under the nut and one under the head. Joints which are bolted only and not
I seal welded are to be made as tight as possible.

3. The joints in the partition baffles need not be absolutely tight but should be made as tight as
J
possible. Buckles on bent flanges which do not clamp properly should be hammered together
1 between the bolts and comers drifted together.

4. All bolted joints are to be retightened after the initial bolting.

.j

\
5. Gaskets shall not be used.

1 6. Joints in feed header are to be absolutely tight. U bolts on the feed header should allow for
> feed header expansion.
 ECONOMISER
I
GENERAL
J The purpose of Economiser is to preheat the boiler feed water before it enters the steam drum and to
-1 recover some heat from the flue gas leaving the boiler.

The inlet and outlet headers are positioned horizontally. It is fed with feed water by a pipe from the
feed water control station. There are two Economiser blocks of each having 35 parallel paths of
Economiser coils connecting the inlet header to the outlet header in each block. The Economiser
coils are horizontally arranged and split into three banks with a gap of minimum of 1050mm in
between them. The Economiser coils are suspended from the Economiser casing top frame through
lugs and pins. There is a link connecting the Economiser outlet header to the drum.

All economiser coil bends are covered by the erosion shield plates which are placed at the top of the
respective economiser bank to minimize the erosion due to fly ash.

FEED WATER CONTROL

The entire boiler water requirement is met by the existing boiler feed pumps. The two numbers, 1 u
100% feed control valve and 1 x 30% feed control valve provided to regulate the flow of feed water
supplied to the boiler. Whenever boiler load less than 30%, the water flows through 30% feed control
valve and above 30% water flows through 100% feed control valve. A motor operated isolation
valves are installed on upstream side of each feed control valve and manually operated valves are
installed on down stream of each control valves. A motor operated regulating valve is provided in the
bypass line to take care of feed water regulation during the maintenance of feed control valve.

MAINTENANCE

Before starting up the boiler, the Economiser should be inspected externally and if necessary
cleaned. Especially if the installation is new, accumulation of erection materials is not unusual. Large
debris should be removed manually followed by washing the Economiser with water.

It should be ensured after water washing that water droplets from Economiser surface are removed
by running the FD and 1D fans which otherwise will lead to corrosion. The external inspection of the
Economiser can be made whenever an opportunity is provided or the draft loss through Economiser
is more than usual, or the heat pick up in the Economiser is less than normal.
 3
SUPERHEATER SYSTEM
i

PRIMARY SWERHEATER
1

i
SECONDARY SUPERHEATER
)

3,
TERITARY SUPERHEATER

_I
TERITARY SUPER HEATER OUTLET TO MAINSTEAM STOP VALVE

PROTECTION AND CONTROL

> MAINTENANCE

.*', L INSPECTION

,
DATA SHEET
'l
SUPERHEATER SYSTEM

In super heater system the super heaters are provided in three stages and termed as primary super
heater, secondary super heater and Tertiary super heater. All the above three super heater are located
at the rear chamber of water wall and the super heater does not exposed to direct radiant zone of
furnace.

PRIMARY SUPERHEATER:
The dry saturated steam from drum is let into the primary super heater inlet header by means of one
number of connecting link. The primary super heater is located just above the evaporator coil. The
primary super heater is horizontally placed, spaced and counter flow arrangement. It consists of 93
parallel paths. The super heater coils are supported on the division wall panel & rear wall panel by
providing the suitable support plate and also clearance has been provided on the both ends for the
differential thermal expansion of water wall and super heater. The super hater headers are placed
behind rear wall panels and the same is supported on the rear wall panel.

SECONDARY SUPERHEATER:
The superheated steam from primary super heater outlet header is let in to the secondary super heater
inlet header by means of connecting links. The secondary super heater coils are located above the
primary super heater coils. The secondary super heater is also horizontally placed spaced and counter
flow arrangement. It consists of 93 parallel paths. Secondary Super heater header and coils are
supported as explained in primary super heater.

TERITARY SUPERHEATER
The superheated steam from secondary super heater outlet is let in to tertiary super heater inlet heater
for further temperature rising to the required level through inlet link. The tertiaq super heater
consists of 93 parallel paths. The tertiary super heater inlet & outlet header are located horizontally
behind the rear wall panel perpendicular to the boiler axis. The super heater coils are horizontally
placed, spaced and parallel flow arrangement. The super heater coils and headers are supported by
the water wall panel similar to the primary super heater.
The desuperheater is provided on the link that connects the secondary super heater outlet header and
tertiary super heater inlet header. De super heating is done by spraying feed water and mixing it with
steam. So that the required outlet steam temperature is obtained. Spray control valve is actuated by
the signal generated by the temperature sensing element which is mounted on the tertiary super
heater outlet steam pipe.
TERTIARY SUPERHEATER OUTLET TO MAIN STEAM STOP VALVE.
The main steam pipe is provided from tertiary super heater outlet header up to main steam
stop valve. The main steam pipe accommodates the following stubs.
1. AIRVENT
2. REMOTE PRESSURE GAUGE
3. PRESSURE TRANSMlTTER
4. SAMPLINGS
5. TEMPERATURE ELEMENT
6. SAFETY VALVE
7. START UP STEAM VENT
8. PRESSURE GAUGE
9. TEMPERATURE GAUGE
10. DRAINSTUB
11. AUXILARY STUB

GENERAL

All super heater coil bends are covered by the erosion shield plates which are placed at the top of the
respective super heater bank to minimize the erosion due to fly ash.

PROTECTION AND CONTROL

As long as there is fire in the furnace adequate protection must be provided for super heater
elements. This is especially important during periods when there is no demand for steam, such as
skirt-up and shut down. During these periods, adequate flow through the super heater is assured by
means of drains and vents in the headers, links and main steam piping.

Super-heater is provided with a safety valve. It is set to pop at a lower pressure compared to the low
set drum safety valve. Hence when there is load fluctuation or when the steam demand drops
suddenly, the flow is established by the lifhng of safety valve.

During all start ups, care must be taken not to overheat the super heater elements by limiting the inlet
gas temperature.

MAINTENANCE

It is essential that suitable arrangements are made to assure cleanliness of the extemal and internal
surfaces of the super heater at all times. Fly ash accumulations result in unequal gas distribution,
inefficient heat transfer and possible localized overheating. The extemal surfaces of the super heater
coils can be inspected using the three access doors provided.
Proper feed water treatment and control of steam quality are essential to assure cleanliness of interior
surfaces of super heaters. Overloads, fluctuating loads, high water level, foaming, high
concentrations etc, all contribute to deposit on interior surfaces. Accumulation of these deposits
inside the tube will lead to overheating failures.

Periodic checks of steam pressure drops across the super heater under identical load conditions
usually indicate whether solid deposits are present with in the elements. In the event of failure of one
or more elements; it is necessary to determine the cause. The manufacturer may be consulted for
repair procedures.

INSPECTION
The following inspection and maintenance programme, conscientiously following very much to
assure continuity of service and to avoid serious and expensive outages.

i. The super heater should always be inspected when the boiler is out of service.

..
11. Check the elements for alignment and any evidence of warping or overheating.
...
111. Check supports spacers and seal plates for proper location and condition. Replace promptly

iv. Check for erosion of tubes

 INLET LINK

INLET HEADER

COIL ARRANGEMENT INLINE

RESTING 'IJPmRT
RESTING SUPPORT (SUPPORT ON THE RESTNG SUPPORT (SUPPORT ON TEE
ON THEDNIS1ON WALL PANEL
TYPE OF SUPPORT DNISION WALL PANEL BY PROVIDE DIVISION WALL PANEL BY PROVIDE
BY THE "ITABLE
THE SUITABLE PLATE.) THE SUITABLE PLATE.)
PLATE.)

TYPE OF SPACER GUDE PLATE GUIDE PLATE GUIDE PLATE

SIZE 0219.1): 15.09mm 0219.1 X 15.09mm&0219.1 X 18.26mm 0219.1 X1826mm
4 OUTLET HEADER MATE- SA106Or. B SA335 P11. SA335 P22
NO. OFF ONE. ONE. ONE.

SIZE 0168.3X7.11THK. 0219.1 X 12.7THK. 0219.1X 12.THK.&0219.1 X 18.26THK.

5 OUTLET LINK MATE- SA 106 GI.B. SA335PII SA 335 PZZ
NO. OFF TWO ONE. ONE.
GENERAL

Desuperheater is provided in the link between connecting the secondary super heater outlet header
and tertiary super heater stage inlet header. This is used to maintain the steam temperature at design
value.

Temperature reduction is accomplished by injecting spray water into the path of the steam through a
holes provided at the venturi nozzle periphery of the pipe at the entering end of the Desuperheater.
The spray water is drawn from the feed pump discharge line but before the feed control station. It is
essential that the spray water be chemically pure and free of suspended and dissolved solids.

CONTROL

A spray control valve linked to an automatic temperature control one number 100% temperature
control valve provided to regulate the flow of spray water supplied to de-super heater. A motor
operated isolation valve is installed on upstream of the control valve and a manual isolation valve is
installed in downstream of control valve to permit isolation when required. A motor operated valve
is provided in the bypass line to take care of the spray during maintenance of spray control valve.

MAINTENANCE

The Desuperheater is fitted with a renewable liner to take care of erosion from the spray water
stream, thus protecting the main Desuperheater shell. Excessive noise from Desuperheater usually
indicates a worn liner and the service department of this company should be contacted when this or
any such abnormal conditions arise. Sufficient clearance should be provided around the
,-\

~ e s u ~ e r h e a tfor
e r replacing liner.
DATA S m E T

NO OFF ONE

SIZE 0273.1 X 15.09 mm

MATERIAL SA335 P11

SPRAY TYPE VENTURI

VENTURI SIZE 0140.8 X 3mm.

VENTURI MATERIAL. SA 240 TP304

NO OF SPRAY HOLES (around ventun nozzle) 2 rows of each 13 nos.

SPRAY HOLE SIZE 0 4 MM

LINER SIZE 0219.1X 3 mm

LINER MATERIAL SA 240 TP304

DESH INLET LINK SIZE 0219.1 x 12.7 mm.

DESH INLET LINK MATERIAL SA 335 PI1

DESH OUTLET LINK SIZE 0219.1 x 12.7 mm

DESH OUTLET LINK MATERIALS SA 335 P l l

,
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AIR AND GAS CIRCUIT
FD AIR SYSTEM

All the required air for the boiler operation is supplied by the hvo FD fans. FD fans are provided
with outlet shut off dampers and inlet regulating dampers. Inlet regulating dampers are operated by
electrical actuator & outlet shut off dampers are pneumatic operated. The cold air from the FD fan
is let into the tubular air heater. The hot air is from the air heater is connected to the two numbers
of FD distribut~onheader which is placed in the front and rear side of furnace. From this each FD
header 3 nos. of duct connected with branch header with pneumatic operated shut off dampers.
Each branch header has 9 nos sporger header on which the air nozzle is provided for fludising the
bed. The fluidising air to the six compartments can be cut off using the pneumatically operated
shut-off dampers provided in the respective compartment air inlet ducts

TUBULAR AIR HEATER

Two blocks air heaters of horizontal type are provided for the boiler at the downstream of
economiser with flow through the tubes and gas flow over the tubes. Cold air from FD fan let into
the air heater which is located at Top and then passed through the bottom block. The regulating
pneumatic operated damper is provided in ducting .between block-I inlet and block-I1 outlet to
control the flue gas exit temperature in low load condition.

DUCTING SYSTEM

All ducts are of Mild steel suitably stiffened on the outside and designed to withstand the pressures
encountered.
-\

~>,

The ducting system is complete with all required expansion joints, mating flanges, dampers,
supports, access doors, platforms insulation etc.
All ducts are of welded construction.

PRIMARY AIR SYSTEM

Two nos of PA fans provided in this system. The suction line for PA fans is from the FD header.
PA fans are provided with outlet shut off damper and inlet regulating dampers. Inlet regulating
damper are operated by electrical actuator and outlet shut off dampers are pneumatic operated. This
helps to isolate one fan when required. The PA fan boots up the pressure of incoming hot air so that
coal can be pneumatically transported in the bed. The PA fan outlet is connected with PA
distribution header
60
From this PA header 6 nos of ducts connected with branch header with pneumatic operated shut off
dampers. Each branch header has four coal transport air pipes feeding a compartment. The coal
transport air to any compartment can be cutoff using pneumatic operated shut off dampers. Each
fuel transportation line has manual operated shut off dampers to facilitate to take individual line
maintenance.

FLUE GAS SYSTEM

The hot gas generated in bed exchanges the heat with the heat transfer surfaces with in the boiler.
The heat is transferred from the flue gases to the water walls, Tertiary super heater, secondary
super heater, primary super heater, evaporator coils placed on second pass of the water wall. The
flue gas temperature further drops while passes through Economiser coils placed in the outside of
furnace. The Boiler to Economiser & Economiser to Air heater gas dueling provides a change in
flow direction of the flue gas. This results in separation of unbumt combustibles and ash from the
flue gas. The separated unbumt combustibles and ash are collected in the hoppers provided below
the Economiser I & I1 and hopper provided below air pre heater and are disposed through suitable
ash removal system. The temperature of the flue gas further reduces it passes through the air heater.
The combustion air is preheated in the air heater by the flue gas.
 FUEL AND ASH SYSTEM
FUEL SYSTEM
)
GENERAL

The type of firing used in this boiler is under bed feeding. The coal is pre-crushed and stored in the
bunkers. The crushed coal is pneumatically transported into the fluidised bed. The air required for
-1
transport of coal is supplied by the primary air fans. There are twelve air lock feeders connected
with six drag chain feeders of split outlet type to feed coal to the twenty four coal feed lines.

The fluidised bed is sectioned into six compartments and each compartment is provided with four
feed points.

, ,

The fuel input rate can be controlled by the use of variable frequency drives bf the rotary air lock
,' 1
feeders. The coal feed lines are provided with sufficient flexibility to clear off choking, if occurs.
I The required air flow can be adjusted using the butterfly dampers provided in the lines.

~1 The crushed coal bunkers are provided with gate arrangement with Moms wheel and chain for the
I purpose of isolation. When the feeders are attended for repair and maintenance.

5
FUEL STORAGE BUNKER
, ,

The twin bunker is designed to take care combination firing as specified earlier
j
The coal bunker is having 240 m3 water volume and coal with reject bunker is having 450 m3 water
- \

volume and SS lining has been provided for the bottom conical portion to avoid sticking of coal in
i
the conical portions. Apart from the above, lime stone bunker of having 90 m3 water volume has
. i been provided.

~1
 The storage hours of different fuels are given in the table.
i

1
TYPE OF FUEL

The coal bunker is having 6 outlet chutes each having rack and pinion gate arrangement with
Morris wheel and chain.
i
j
The adequate size of mini bunkers with SS lining is provided below bunker outlet chutes and same
have been mounted above the pocket feeders.
.j

1 The liberally sized non-glogging type pocket feeder are provided to take care of feeding and
: regulating the required fuel for firing.

The variable frequency drives are provided to control fuel feeder speed in order to convey the fuel
quantity.

DRAG
-
CHAIN FEEDER
\

Therotary feeder outlet from each bunker is connected with drag chain feeder the total no. off
feeders are 6 nos each one number per compartment. Drag chain feeder is provided with constant
speed drive. The feeder outlet chute is divided into four chutes and connected with mixing nozzle
mounted on the fuel transportation line.

FUEL DISTRIBUTING SYSTEM

The fuel from the feeding points is pneumatically transported through fuel feed pipe to the fluidised
bed. Forced air flow to each of the bed compartments can be isolated independently by dampers. A
damper is provided in the air ducting to each bed section. The number of feeding points are 24
(under bed) and are located in the bed in such a way for uniform fuel distribution
 ASH SYSTEM
Ash generated from the boiler is collected at following location as given bellow.

1 1
SL. NO LOCATION 1 NO. OF HOPPER 1
/ 1 I Fludiesed Bed Compartment Hopper 1 6 Nos. 1
Furnace Rear Pass Hopper 1 6Nos

Econorniser Block-I I , 1No.

Economiser Block-I1 1 1No.

5 1 Airheater
6 1 Electrostatic Precipitator I 4 Nos.

This boiler is designed for high ash fuel

The compartment hopper initially filled with bed material at the time of boiler starting. After boiler
running the bed ash slowly will built up in the hopper itself and the bed ash will be drained at the
bottom of the hopper gate by manual.

The gate is provided with pneumatic operated knife edge gate. The bottom drain shall be made for
;,emergencypurpose and when the bed build up rate is high. Excessive pressure drop in the bed shall
be used an indication to operate the bonom drain of bed.

As cQ1lected at furnace Rearpass, Economiser, air heater, electrostatic precipitator hoppers are
disposed through ash handling system. All the hopper as provided with over flow pipe with
isolation gate arrangement to facilitate the disposal of ash while ash handling system in
maintenance.
DOSING SYSTEM
HP DOSING

In HP dosing system, trisodium phosphate is dosed lo steam drum to precipitate the dissolved salts
forming hardness. These precipitated sludge is removed through blow down to ensure proper
dosing of phosphate recommended amount of residual phosphate is maintained in the blowdown.
The amount of required residual phosphate can be obtained from phosphate curve which depends
on the pH value of boiler water.

DESCRIPTION

DM water is mixed with trisodium phosphate in mixing tank and stored tank. Water is thoroughly
mixed with chemicals using molorised agitator. Prepared chemical is dosed to drum using
reciprocating pump. The flow of reciprocating pump can be varied by adjusting the stroke of the
plunger through a scaled knob. At the pump discharge a pressure gauge is provided to read the
pump discharge pressure. One no. of pressure relieving valve is provided lo safeguard the pump
against high pressure. Necessary isolation valves are provided to isolate the pump. One no of NRV
is provided in the pump outlet to prevent the back flow of water to the pump

PROCEDURE:

When the boiler is under normal operation chemical is dosed. at a particular rate and boiler
blowdown sample is analysed for residual trisodium phosphate. Based on analysis increase or
decrease the dosing rate to get the required residual phosphate(P04). Once the required residual
,,phosphate is obtained note the stroke and chemical concentration (Ratio of watedP04) which
should not be varied unless there is any change in the feed water quality.

HANDLING AND STORAGE:

1. Avoid contact with skin and eyes

2. Avoid extremes of temperature
3 Replace caps securely after use.
4 Maximum storage limit is 2 years
 FLUIDISED BED COMBUSTION

FLUIDISED BED

When air or gas is passed through an inert bed of solid particles such as sand supported on a fine
mesh or grid, the air initially will seek a path of least resistance and pass upward through the sand.
With further increase in the velocityl the air bubbles through the bed and the particles attain a state
of high turbulence:Under such conditions, the bed assumes the appearance of a fluid and exhibits
the properties associated with a fluid and hence the name Fluidised Bed.

MECHANISM OF FLUIDISED BED COMBUSTION

If the sand, in a fluidised state, is heated to the ignition temperature of the fuel and the fuel is
injected continuously into the bed, the fuel will bum rapidly and the bed attains a uniform
temperature due to effective mixing. This, in short, is fluidised bed combustion..

While it is essential that temperature of bed should be at least equal to ignition temperature of fuel
and it should never be allowed to approach ash fusion temperature (1050°C to 1150°C) to avoid
melting of ash. This is achieved by extracting heat from the bed by conductive and convective heat
transfer through tubes immersed in the bed.

If velocity is too low, fluidisation will not occur and if the gas velocity becomes too high, the
particles will be entrained in the gas stream and lost. Hence to sustain stable operation of the bed, it
must be ensured that gas velocity is maintained between minimum fluidisation velocity and particle
'entrainment velocity.

ADVANTAGES OF FBC BOILERS

1. Considerable reduction in boiler size is possible due to high heat transfer rate over a small heat
transfer area immersed in the bed.

2. Low combustion temperature of the order of 750" - 900°C facilitates burning of coal with low
ash fusion temperature, prevents NOx formation, reduces high temperature corrosion and
erosion, and minirnises accumulation of harmful deposits due to low volatilisation of alkali
components.

3. High sulphur coals can be burnt efficiently Without much generation of SOX by feeding
limisestone continuously with the fuel.
4. The unit can be designed to bum a vanety of fuels including low grade coals like floatation
slimes and washery rejects without much sacrifice in operation efficiency, because only about
1% by wt. of carbon content in the bed c~ sustain the fluidised bed combustion.

5. High turbulence of the bed facilities quick start-up and shut down.

6. Full automation of start-up and operation using simple reliable equipment is possible.

7. Inherent high thermal storage characteristics can easily absorb fluctuations in fuel feed rate.

8. There is reduced possibility of formation of local hotspots on heat transfer surfaces

9. Though having comparatively low efficiency, fluidised bed coal fired boilers offer the following
distinct advantages over pulverised coal fired boilers, especially when using low rank coals :-

(i.) High thermal inertia helps to overcome the problems of flame stability. It eliminates the
necessity of supplementary oil firing to prevent extinction of flame' when moisture and
ash content of coal are high.
(ii) The formation of sticky deposits on the fire side of the tubes because of lowering of ash
h i o n temperature by sodium components in ash in avoided due to low bed temperature.

(iii) Lower coal crushing cost due to higher particle size

10. Efficiency of 80% and above can be achieved

HSV 038 HSV 038
t
 WATER QUEITY REQUIREMENT FOR SINGLE DRUM BOILERS

DRUM OPERATING PRESSURE (Kglem2(g))

ABOVE 60
FEED WATER:

Specific electrical conductivity at 25"c measured after cation

exchanger in the h+ form and after co2 removal.
I mlcm I m. I 0.5 I
Total Iron PPm max. 0.01
Total copper PPm max. 0.01
Total Silica PPm max. 0.02
o~gen PPm max. 0.007
Hydrazine residual rPIn max. 0.01-0.02
I pH AT 25" C (Copper Alloy Pre-Boiler System) I ppm I max. 1 8.8-9.2 1
pH AT 25" C (Copper Free Pre-Boiler System)

PPm max. Nil

1 Hardness PPm Nil
Total COz PPm Nil
Not
PPm Allowed
I BOILER WATER I
I Tot? dissolved solids I
w
I Not more I
PPm

I Specific electrical conductivity at 25" c I mslcm

Not more

9.8-10.2
Silica level
less than 0.02
ppm in steam
leaving the
 NOTES:
1. All the measurement of feed water shallbe made at high pressure heater outlet or Economiser inlet.

2. The recommended pH in feed water can be obtained by dozing ammonia morpholine or any volatile
amine. The concentration of volatile chemical in the feed water should not exceed 1 ppm (expressed
as ammonia).

3. If the pH of boiler water fails below the recommended range, it will considerably increase silica
cany over in steam and hence suitable lower silica level should be maintained in boiler water to
maintain less than 0.02 ppm in steam leaving the drum.

4. The phosphate and pH are recommended in accordance with co-ordinated phosphate curve to
prevent presence of free hydroxide in boiler water. If the recommended pH is consistently obtained
phosphate residual can be maintained near lower limits.

5. Water levels' in drum should be maintained within limits during all operational modes ie., Start-up,
load fluctuation and normal operation.

I
6. The alignment of drum internal should be checked and ensured to be in order at least once in every
] year.

i
7. It is needless to emphasize that correct sampling, accurate measurements with the use of reliable
insbxments at adequate intervals and proper logging of reading go a long way in ensuring trouble
,\ free operation of boilers.

8. To be controlled on the basis of silica in boiler water and drum pressure and boiler water pH
rebtionship to maintain less than 0.02 ppm in the steam leaving the drum.
.J
 DRUM PRESSURE kg/cm2 (g)

RECOMMENDED MAXMIUM SILICA

CONCENTRATION IN BOILER WATER
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 PROCEDURE FOR HYDROSTATIC TESTING
! The complete system of boiler components, along with all interconnecting piping should be
hydrostatically tested before start-up to comply with code requirements and to check for leaks. The boiler

'1 and process lines must be completely vented in order to fill them with water

9 The following is a recommended procedure for hydrostatic testing:

1. Open the steam drum vent valve and close steam outlet valve.

2. The boiler safety valve stubs are to be plugged with end plates and the same have to be cut and
removed after hydro test and the safety valves are to be butt welded.

3. For subsequent hydro test if any and for every annual hydro testing gag the safety valves in
accordance with safety valve manufacturer's recommendations. In lieu of gagging, the safety valves
may be removed and replaced with test plugs or blind plates.

4. Isolate pressure switches, gauge glasses or control components which are not intended to be subjected
to a hydrostatic test.

5. Fill the system with treated water in accordance with recommended LSlL water quality. The
temperature of water used shall not be less than 20°C and greater than5O0C.

6. Once the system is filled and the pressure is approximately 1 kglcmz, close all vents. The pressure
may then be increased gradually to the test pressure requirement of the local steam boiler inspecting
agency. Do not subject any pressure part to more than 1-112 times the design pressure rating of the
component.

'-) 7. Examine the system for any leaks. If no leaks are visible, hold the system in a pressurized static
condition -for a period of 112 hour to satisfy the code requirements.
8. After that the pressure shall be reduced to maximum allowable working pressure and maintained for
sufficient time to permit close visual inspection for leakage of pressure parts.
.J 9. upon completion of the test, release pressure slowly through a small drain valve. Then fully open the
:.I vents and drains when the pressure drops to 1 KgIcm2 (g). Particular care must be given to make sure
that parts not normally containing water during operation are drained free of water. The system
.? should be drained fully after hydrostatic testing to prevent freezing, if the unit is installed in a cold
- weather area, and to minimize corrosion of the metal surfaces.

.$ 10. If temporary hand hole or manhole gaskets were used for the test, they should be replaced with
regular service gaskets before reading the unit for operation. Gaskets should never be reused. Replace
1
gauge glass if necessary and make sure that the gauge cocks are open. Remove all blanks or gags
from safety valves and install safety valves; if removed.
 PROCEDURE FOR ALKALI BOILOUT

1. Check boiler erection work is completed with all assemblies, valves, fittings and necessary
instrumentation.

2. Boiler auxiliaries such as fans, feed pumps should have been trial run and made ready for operation.

3. Check boiler instrumentation and control panel are ready for regular operation. But the following
instruments are to be isolated for alkali boil out.

I) Flow, pressure and level transmitters,

11) Pressure switches.

4. Ensure steam drum intemals have been fixed. in position.

5. Check all the refractory and insulation work are completed.

6. Check all scaffolding, temporary supports, debris are cleared.

7. Ensure slow firing is done as per the slow firing procedure.

8. Check suitable fire fighting equipments such as C02 or foam type fire extinguishers, sand buckets, etc,
are available at suitable convenient places.

9. Check boiler chemical feeding system is ready for operation.

10. Check sufficient quantity of chemicals are available. Based on the water volume of the boiler the
chemicals required can be estimated. If water volume of the boiler is Q ~ ^ each
3 chemicals required
will be 4 x Q kgs. The same quantity of chemicals will be required for each boil out.

11. Foralkali boilout sodium carbonate and trisodium phosphate are used
1 12. Prepare 20% concentrated solution of the chemicals separately in a drum and the solution is charged
;

> in to the boiler through the nozzles (either auxiliary steam top nozzle or Air vent nozzle) in to the
) drum manually by means of funnel.
13. After the addition of chemicals in to the required quantity, the nozzles are covered with the cover

-1 flange and fill up water to the normal operating level.

~~j 14. Light up the boiler and raise the steam pressure is gradually to 5 ata as per standard operating
! procedure and maintain the pressure for minimum period of 12 hours.
,
 7
15. Tighten all glands and flange joints

16. Raise the firing rate to achieve a boiler loading of nearly of the normal loading rate of the boiler
,
1 17. Samples to be taken every two hours and analysis is to be carried to determine the following:

) a) Ph value
.1 b) Alkalinity

J c) Phosphate
d) Oil
'7
I c) Silica

18. Ensure the pre-commissioning activities are canied out as per the commissioning check list.

19. Ensure the Alkali Boilout is carried out in 3 stages and fresh chemicals are changed before each
stage.

20. Ensure the pressure is maintained in the boiler for each stage alkali boilout as'

follows:
DURATION
I stage 5 kgicmsq. - 12 hours.
I1 Stage 7 kgicm sq. - 12 hours
I11 Stage 10 kglcm sq. - 12 hours
(Ensure the pressure of the boiler is raised gradually for alkali boilout)
21. Each stage of boiling can be terminated when the content of oil in the boiler water maintains a steady
value. However final reading of oil should be less than 5 ppm.
- \

22. After termination of boilout procedure, shut down the boiler and allow the unit to cool down
gradually.

23. Drain the boiler after the drum pressure reaches atmospheric pressure. Water jets shall be used to

clean the headers.

24. After complete draining of boiler, clean the complete unit by filling the water and drain it for atleast
.one time. The hand hole pipes of all headers preferably at bottom most point to be cut and inspected for
any foreign materials availability and to be cleaned.

25. After inspection and cleaning reweld the end caps &d hydro test the boiler to working pressure.

26. Now the boiler is ready for steam blowing.

PROCEDURE FOR STEAM BLOWING

STEAM BLOWING

Steam blowing is an established practice for the purpose .of physically removing any substance which
remain deposited in the superheater and associated pipe lines. These substances are mainly scales and
loose minerals that might have been entrapped during manufacture, storage and erection at site.

PRINCIPLE

The principle of steam blowing is to give thermal shock and dislodge the scales. These scales will be
subsequently driven out by the dynamic velocity of the expanding steam Before starting the boiler for
steam blowing the following points are to be ensured:

1. Alkali boilout is completed,

2. All the instruments calibration are completed and safety interlocks are in line, except water level
interlock which is to be isolated temporarily.

3. NRV and flow nozzle should not be fitted initially and thermowell in steam line is to be removed.

4. All the spring hangers in steam line are loaded properly.

5. Temporary steam line is erected and anchored properly for steam blowing

6. Target plate fixing arrangement to be kept ready

7. ~e-quired
target plates are to be machined and kept ready to fix when required. Target plates shall be
of aluminum material.
 PROCEDURE:

The method of steam blowing is as below:

1. Operate with one compartment and raise the boiler pressure above 35 kg/cmn2.The bed temperature
shall be maintained at about 800-950°C.

2. Quickly open the main steam stop valve (or the temporary blowing valves if provided). In order to
maintain the flow to atmosphere the main steam stop valve is to be kept open till the steam pressure
drops down close to 16 kg/cm2.

3. Slowly reduce the firing rate and slump the boiler. The main steam stop valve shall be closed when
the boiler pressure reaches 16 kg/cm2

4. After one hour, the boiler shall be restarted with one compartment and the bed temperature shall be
maintained at about 800 - 950°C.

Thc steam blowing shall be once again started when the pressure reaches 35 kg/cm2. By the above
procedure, the scale adhering to the contours get cracked due to temperature difference and get removed
to subsequent blows.

SCHEME OF BLOWING
Temporary discharge piping which lead the steam to the atmosphere shall be welded downstream
of main steam line must be properly supported and anchored.

OPERATIONAL PRECAUTIONS
- \

1. Norinally the steam blowing operation is the first occasion to fire the unit at significant rate. The unit
must be brought up much slower while all equpments are checked and expansion movements are
.) monitored closely
I
2. During blowing, water level in drum gauge glass may fluctuate very widely. Feed regulating station
j must be checked for proper remote operation. Sufficient quantity of D.M water availability muse be
-I ensured.

, 3. Flue gas temperature at the inlet olconvection superheater must be restricted to 450°C

4. Temporary discharge piping whch should be atleast cqual to the diameter of piping to which it is
connected must be well supported to withstand reaction forces during steam blowing.
 PROCEDURE FOIt SI,OW FIRIKG
REFRACTORY DRY OUT:

After the refractory works are finished, the refractory work must be subjected to proper curing
and initial heating. These two procedures must be strictly canied out. Otherwise, cracks may occur on the
refractory surface. These procedures are explained below.

CURING FOR CASTABLE REFRACTORY:

All the castable are hydraulic setting and need the presence of moisture for setting process, so it is
necessary to ensure that the castable does not dry out to exposure or due to heat produced within the
mass. It should not be allowed to dry during first 24 hours after it has been placed.

Moist condition has to be maintained by covering the castable with wet gunny sacks or by frequent
sprinkling of fine mist of cold water on all exposed surfaces. Sprinkling should be stated after the
castable has set partially. It is generally advisable to spray water on dense castables every 45 minutes for
hours.

INITIAL HEATING FOR CASTABLE REFRACTORY:

Proper attention should be given during initial heat up of castables, as they have considerably
lower permeability when compared to brick. It is more difficult for the water to pass through the castable
and escape as the refractory is heated more rapidly. So due to this, high pressure steam is developed
inside the brick and this ruptures the lining.

Rapid heating also causes the hot face to dry up and heat up while the rest of castables is st111
comparatively cool. This will lead to expansion of hot face and hence develops a crack on cold face.

SLOW FIRING PROCEDURE :

Following are to be done before slow firing is stated:
a) All the coal nozzles and air nozzles must be hlly covered with bed materials
b) No fans should be operated for the heating purpose. Firing should be done only by natural draught.
For this all dampers should be kept open.
c) Sufficient sized fire wood required has to be stocked for the dry out.
The following heat and curing, schedule is recommended:
1.Heat gradually up to 110°C and hold at this temperature for six hours.

2. Then raise the temperature at the rate of 10°C per hour up to 550°C and hold at this temperature for
six hours.
S T A R T U P PROCEDURE FOR OIL BURNER
SYSTEM
START UP ROCEDURE FOR OIL BURNER SYSTEM

START UP PROCEDURE:
As this boiler is having start up oil bumer system separately to make the start up very convenient.

The total Qty. of charcoal requirement will be approximately 12 - 15% of the qty. of bed material
in the start up compartment. As the charcoal addition is done during fluidising condition, the fluidisation
will get ai'iected due to the additional weight of charcoal. The drag force required to fluidise the new bed
material & charcoal mixture will be more. Hence increasing of air flow by observing the bed condition is
a must during charcoal charging. Keeping unnecessarily more air (or) more PA header pressure (ie.
above 900 mmwc) may throw the charcoal to the adjacent compartment which will lead to localised
clinker formation in the compartment border due to static burning. During this cold fluidisation study and
charcoal charging, the bumer combustion air should be kept in open condition to avoid chocking of
bumer lines.

Start the oil pump and allow the oil to circulate through the return oil line for some time, throttle
the oil return line valve to increase the oil pressure - 7 to 10 kg/cm2.
Now start the bumer one by one as per following procedure.
1. Keep minimum oil and minimum atomising air open.
2. Ignite the bumer by swab through the ignition hole.
3. Increase the oil flow and atomising air flow.
4. Observe the flame length and colour. It should be yellowish violet. This is to be achieved by proper
adjustment of atomising and combustion air.

In case if flame cut off occurs during start up, immediately that parlicular bumer oil to be stopped
and bumer light up to be done as per procedure explained above.
,-\
All the charcoal which are in fluidised state will get ignited by bumer flame. Keep this condition
for 10 minutes to allow all the charcoal to get fire. Now decrease the fluidising air flow little bit to avoid
rapid burning of charcoal. Keep this condition for 2 to 5 minutes. Slowly all the bed material will get red
hot. During this period closely watching of bed condition is a must to avoid quenching of fire in bed and
delaying of temp, pick up due to excess air. Now all the bed temperature will increase fastly, once it
reaches 600°C set MCR air flow, for 1 compartment stop oil pump and start fuel feeder.

Set optimum feeding and ensure coal catches fire in the start up compartment. Now the bed
temperature to be maintained between 850 - 900' C by regulating feeders RPM.
 DOILER OPERATISG ISSTRUCTIOSS

01. STARTING OF ALL INDIVlDUAL EQUIPMENTS

02. DPSTUDY

03. BED MATERIAL, CHARCOAL. KEROSENE & OIL REQUIREMENT

04. BOILER LIGHT UP

05. NORMAL OPERATION

06. NORMAL SHUT DOWN TO COLD

07. NORMAL SHUT DOWN TO HOT STAND BY

08. HOT RESTART

STARTING OF ALL INDIVIDUAL EQUIPMENT

GENERAL

The boiler is provided with interlocks for safe and reliable operation and none of these should be
bypassed.
The sequence of starting of the equipments is as follows:
Check water level gauge for water in Drum.
1. Start the ID fan.
2. Start the PA fan.
3. Start the FD fan.
4. Start the Fuel feeders.

Similarly while switching off, reverse sequence must be followed

The individual equipment can be started through DCS or from Local' Push Button (LPB). Switch on the
power supply to the motor control centre (MCC) panel. The fuses of individual -motor controls shall be
checked for continuity. Three phase supply of 415. V 111000 V 50 Hz with allowable percentage of
variation shall be ensured before switching on the equipment.
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THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYOS STEEL INDUSTRIES LIMITED.
AN0 MUST NOT BE C O P E 0 OR LENT WITHOUT THEIR PERMISSION IN WRITING.
IF IN DOUBT .
PLEASE ASK.
DO NOT SCALE THE DRG.
SYMBOLS:
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ID FAN-I (Drawing No. 8005-00-00-2-003)
AFBC is provided with 2 ID fans. Two ID fan motors are required to run the boiler at 100% MCR
Each ID fan is provided with inlet control damper at its suction.

ON-SEQUENCE OPERATION:
Before starting the ON sequence operation of ID fan, the system shall ensure the following conditions.
1. ID fan -I regulating vane should be at minimum position.
2. Close ID fan -I delivery damper.
Each ID fan is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that ID fan shall be initiated.
The starting impulse generated by the push button shall set the memory which shall reset automatically
after the starting sequence is completed.

ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the start command of ID fan will be set provided the
following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.
a) ID fan-I bearing temperature at drive end not high.
b) ID fan-I bearing temperature at non-drive end not high.
c) ID fan-l suction damper at closed position.
d) ID fan-I delivery damper at closed position.
e) Steam drum level normal.
switch gear clearance 0.K
g) ID fan-I1 running (or) ID fan-I1 suction damper closed.
Whenthe permissive conditions (a) to (g) are available, a white LED shall glow on the DCS; indicating
the availability of all the permissive conditions.
ID FAN-I ON:
The following actions shall be initiated after starting of ID Fan-I.
1. ID fan-I delivery damper shall open.
After the elapse of preset starting time (adjustable)-and fulfillment of the above condition "ON" sequence
complete" condition is indicated by a white LED.
If the above condition is not satisfied and a preset starting time (adjustable) has elapsed, ON-sequence
fail condition is indicated by amber LED glow. "ON sequence' complete" and "ON sequence fail"
conditions are recorded in the system. ON-sequence start memory will be reset automatically after a
preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions are indicated.
OFF SEOUENCE OPERATION:
Upon pressing this push button, the OFF sequence operation of the ID fan shall be in~tiated.The impulse
generated by the push button shall set the OFF-sequence memory and trip the ID fan and also initiate the
following conditions.
a) ID fan-I outlet damper closed.
b) ID fan-I suction damper (regulating) closed.
If the above conditions are satisfied and after elapse of preset stop time the "OFF-sequence complete"
condition is indicated by white LED glow or otherwise "OFF-sequence fail" condition will be indicated
by amber LED allow.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.

TRIPPING CONDITION:
The running ID fan shall trip under following condition.
a) 1D fan motor overload.
b) ID fan bearing temperature (DEiNDE) very high.
i) The condition (b) will be connected directly to the MCC.
ii) Local stop push button pressed is wired directly to MCC.

ID FAN-I:
Following actions shall be initiated automatically.
i) Suction and delivery damper of ID fan-I closes.

GENERAL NOTES:

1. When the LocallRemote switch in VFD panel is in local mode, the motor can be started either from
local or from VFD panel without any interlocks. When the LocallRemote switch is in remote mode,
the motor can be operated from DCS with all the necessary interlocks stated above.
2. Both ID fan-I and I1 motor shall be operated to get 100% capacity.

3. Check back signals should be available for all the signals.

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ID FAN-I1 (Drawing No. 8005-00-00-2-004)
AFBC is provided with 2 ID fans. Two ID fan motors are required to run the boiler at 100% MCR
Each ID fan is provided with inlet control damper at its suction.

ON-SEOUENCE OPERATION:
Before starting the ON sequence operation of ID fan, the system shall ensure the following conditions.
1. ID fan - I1 regulating vane should be at minimum position.
2. Close ID fan - I1 delivery damper.
Each ID fan is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that ID fan shall be initiated. The starting
impulse generated by the push button shall set the memory which shall reset automatically after the
starting sequence is completed.

ON-SEOUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the start command of ID fan-I1 will be set provided
the following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.
a) ID fan-I1 bearing temperature at drive end not high.
b) ID fan-I1 bearing temperature at non-drive end not high.
c) ID fan-I1 suction damper at closed position.
d) ID fan-I1 delivery damper at closed position.
e) Steam drum level normal.
f)". Switch gear clearance O.K.
g) ID fan-I running (or) ID fan-1 suction damper closed.
Whenthe permissive conditions (a) to (g) are available, a white LED shall glow on the DCS; indicating
_r.

the availability of all the permissive conditions.

ID FAN-I1 ON:
The following actions shall be initiated after starting of ID Fan-11.
1. ID f a n 4 delivery damper shall open.
After the elapse of preset starting time (adjustable) and fulfillment of the above condition "ON" sequence
complete" condition is indicated by a white LED.
If the above condition is not satisfied and a preset starting time (adjustable) has elapsed, ON-sequence
fail condition is indicated by amber LED glow. "ON sequence complete" and "ON sequence fail"
conditions are recorded in the system. ON-sequence start memory will be reset automatically after a
preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions are indicated.
 \
OFF SEQUENCE OPERATION:
. ,

Upon pressing this push button? the OFF sequence operation of the ID fan shall be initiated. The impulse
I-.!. generated by the push button shall set the OFF-sequence memory and trip the ID fan and also initiate the
,. -
i following conditions.
-> a) ID fan-I1 outlet damper closed.
b) ID fan-I1 suction damper (regulating) closed.
>
-, If the above conditions are satisfied and after elapse of preset stop time the "OFF-, sequence complete"
I
condition is indicated by white LED glow or otherwise "OFF-sequence fail" condition will be indicated
1 by amber LED glow.
>, "OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence

L i
start memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or
"OFF-sequence fail" conditions are indicated.
';
:. 1
TRIPPING CONDITION:
. ~
! The running ID fan shall trip under following condition.
.) a) ID fan motor overload.
b) ID fan bearing temperature (DE/NDE) very high.
1
i) The condition (b) will be connected directly to the MCC.
ii) Local stop push button pressed is wired directly to MCC
i
ID FAN-11:
Following actions shall be initiated automatically,
i) Suction and delivery damper of ID fan-I1 closes.
,,
~,.

GENERAL NOTES:
1. When the LocalIRemote switch in VFD panel is in local mode, the motor can be started either
from local or from VFD panel without any interlocks. When the LocalIRemote switch is in
remote mode, the motor can be operated from DCS with all the necessary interlocks stated
above.
2. Both. ID fan-I and I1 motor shall be operated to get 100% capacity
3. Check back signals should be available for all the signals.
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 PA FAN-1 (Drawing No 8005-00-00-2-005)
! AFBC is provided with 2 PA fans. Any one PA fan motor is required to run the boiler at 100% MCR
Another one PA fan will be stand-by
Each PA fan is provided with inlet control damper at its suction.
)

-1 ON-SEQUENCE OPERATION:
)
Before starting the ON sequence operation of PA fan, the system shall ensure the following conditions

1. PA fan-I regulating vane should be at minimum position.

2. Close PA fan4 delivery damper.
Each PA fan is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that PA fan shall be initiated. The starting
impulse generated by the push button shall set the memory which shall reset automatically after the
starting sequence is completed.
3. Check back signals should be available for all the signals.

ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the start command of PA fan will be set provided the
following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.

a)PA fan-I bearing temperature at drive end not high.

b) PA fan-I bearing temperature at non-drive end not high.
c) PA fan-I suction damper at closed position.
d) PA fan-I delivery damper at closed position.
e) ID fan-I or ID fan-I1 running.
f) ~ w i t i hgear clearance O.K.
g) PA fan-I1 suction damper closed.
When the permissive conditions (a) to (g) are available, a white LED shall glow on the DCS, indicating
the availability of all the permissive conditions.

PA FAN-I ON:
The following actions shall be initiated after starting of PA Fan-I
1. PA fan-I delivery damper shall open

After the elapse of preset starting time (adjustable) and fulfillment of the above condition "ON" sequence
complete" condition is indicated by a white LED.
If the above condition is not satisfied and a preset starting time (adjustable) has elapsed, ON-sequence
fail condition is indicated by amber LED glow. "ON sequence complete" and "ON sequence fail"
conditions are recorded in the system. ON-sequence start memory will be reset automatically after a
preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions are indicated.

OFF SEQUENCE OPERATION:

Upon pressing this push button, the OFF sequence operation of the PA fan shall be initiated. The impulse
generated by the push button shall set the OFF-sequence memory and hip the PA fan and also initiate the
following conditions.

a) PA fan-I delivery damper closed.

b) PA fan-I suction damper (regulating) closed.
c) ID fan4 not running.
d) ID fan-I1 not running.
If the above conditions are satisfied and after elapse of preset stop time the "OFF-sequence complete"
condition is indicated by white LED glow or otherwise "OFF-sequence rail" condition will be indicated
by amber LED glow.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.

TRIPPING CONDITION:
The running PA fan shall trip under following condition.
a) PA fan motor overload or
b) PAfan bearing temperature (DE) very high or
c) PA fakbearing temperature (NDE) very high.

i) The condition (a) will be connected directly to the MCC.

ii) Local stop push button pressed is wired directly to MCC.

PA FAN-I:
Following actions shall be initiated automatically.
i) Suction and delivery damper of PA fan-I will be closed
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PA FAN-II:(Drawing No. 8005-00-00-2-006)
AFBC is provided with 2 PA fans. Any one PA fan motor is required to run the boiler at 100% MCR.
Another one PA fan will be stand-by.
Each PA fan is provided with inlet control damper at its suction.

ON SEQUENCE OPERATION:
Before starting the ON sequence operation of PA fan, the system shall ensure the following conditions.
1. PA fan-ll regulating vane should he at minimum position.

2. Close PA fan-I1 delivery damper.

Each PA fan is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that PA fan shall be initiated. The starting
impulse generated by the push button shall set the memory which shall reset automatically after the
starting sequence is completed.

ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the start command of PA fan will be set provided the
following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.

a) PA fan-I1 bearing temperature at drive end not high.

b) PA fan-I1 bearing temperature at non-drive end not high.
c) PA fan-I1 suction damper at closed position.
d)PA fan-I1 delivery damper at closed position.
e) ID fan-I or ID fan-I1 running.
f) Switch gear clearance 0.K
g) PA^&-I suction damper closed.
When the permissive conditions (a) to (g) are available, a white LED shall glow on the
DCS, indicating the availability of all the permissive conditions.

PA FAN-I1 ON:
The following actions shall he initiated after starting of PA Fan-11.
1. PA fan-I1 delivery damper shall open.

After the elapse of preset starting time (adjustable) and fulfillment of the above
condition "ON" sequence complete" condition is indicated by a white LED.
If the above condition is not satisfied and a preset starting time (adjustable) has elapsed; ON-sequence
fail condition is indicated by amber LED glow. "ON sequence. Complete" and "ON sequence fail"
 i
conditions are recorded in the system. ON-sequence start memory will be reset automatically after a
preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions are indicated.

OFF SEQUENCE OPERATION:

? Upon pressing this push button, the OFF sequence operation of the PA fan shall be initiated. The impulse

-\ generated by the push button shall set the OFF-sequence memory and trip the PA fan and also initiate the
following conditions.

a) PA fan-I1 outlet damper closed.

b) PA fan-11 suction damper (regulating) closed
c) ID fan-I not running.
d) ID fan-I1 not running.
If the above condition are satisfied and after elapse of preset stop time the "OFF-sequence complete"
condition is indicated by white LED glow or otherwise "OFF-sequence fail" condition will be indicated
by amber LED glow.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete "or" OFF-
sequence fail" conditions are indicated.
TRIPPING CONDITION:
The running PA fan shall trip under following condition.
a) PA fan motor overload or
b) PA fan bearing temperature (DE) very high or
c) PA fan motor bearing temperature (NDE) very high.
'%, i) The condition (a) will be connected directly to the MCC.
ii) Local stop push button pressed is wired directly to MCC.
PA FAN-11:

1 Following actions shall be initiated automatically.

i) Suction and delivery damper of PA fan-11 will be closed
-)
' \ GENERAL NOTES:
. _j

-j
1. When the LocalIRemote switch in MCC is in local mode, the motor can be started either from local
or MCC without any interlocks. When the LocalIRemote switch is in remote mode; the motor can be
1 operated from DCS with interlocks.
-3 2. Either PA fan-I and I1 motor shall be operated to get 100% capacity.
,
3. Check back signals should be available for all the signals
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FD FAN-I: (Drawing No8005-00-00-2-007)
AFBC is provided with 2 FD fans. Two ED fan motors are required to run the boiler at 100% MCR. Each
FD fan is provided with inlet control damper at its suction.

ON-SEQUENCE OPERATION:
Before starting the ON sequence operation of ED fan, the system shall ensure the following conditions.
1. FD fan -I regulating vane should be at minimum position.
2. Close ED fan -I delivery damper.
Each FD fan is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that FD fan shall be initiated. The starting
impulse generated by the push button shall set the memory which shall reset automatically after the
starting sequence is completed.

ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the start command of FD fan will on set provide the
following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.
a) ED fan-I bearing temperature at drive end not high.
b) FD fan-I bearing temperature at non-drive end not high.
c) FD fan-I suction damper at closed position.
d) FD fan-I delivery damper at closed position.
e) PA fan-I (or) PA fan-I1 running.
f) Switch gear cIearance O.K.
g) FD fan-I1 suction damper closed (or) FD fan-I1 motor running.
h) Furhace pressure normal.
Whenthe permissive conditions (a) to (h) are available, a white LED shall glow on the
DCS, indicating the availability of all the permissive conditions.

FD FAN-I ON:
The following actions shall be initiated after starting of FD Fan-I.
1. FD fan-I delivery damper shall open.
After the elapse of preset starting time (adjustabie) and fulfillment of the above condition "ON" sequence
complete" condition is indicated by a white LED.
If the above condition is not satisfied and a preset starting time (adjustable) has elapsed, ON-sequence
fail condition is indicated by amber LED glow. "ON sequence complete" and "ON sequence fail"
 conditions are recorded in the system. ON sequence start memory will be reset automatically after a
preset time delay, after he ON-sequence complete 'or' ON-sequence fail conditions are indicated.
I OFF SEOUENCE OPERATION:

' I Upon pressing this push button, the OFF sequence operation of the FD fan shall be initiated. The impulse
.
,- generated by the push button shall set the OFF-sequence memory and trip the FD fan and also initiate the

,' following conditions.

a) FD fan-I delivery damper closed.

3
b) FD fan-I suction damper (regulating) closed
3 c) PA fan-I motor not runmng.
\
d) PA fan-I1 motor not running.
If the above condition are satisfied and after elapse of preset stop time the "OFF-sequence complete"
condition is indicated by white LED glow or otherwise "OFF-sequence fail" condition will be indicated
by amber LED glow.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
> memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
\. sequence fail" conditions are indicated.

TRIPPING CONDITION:
The running FD fan shall trip under following condition.
a) FD fan motor overload.
b) FD fan bearing temperature (DE) very high.
c) FD fan bearing temperature (NDE) very high.
d) Furnace pressure high.
i) The condition (a) will be connected directly to the MCC.
ii) Local stop push button pressed is wired directly to MCC.
FD FAN-I:
Following actions shall be initiated automatically.
i) Suction and delivery damper of FD fan-1 will be closed.
GENERAL NOTES:
1. When the LocallRemote switch in VFD panel is in local mode, the motor can be started either from
local or VFD panel without any interlocks. When the LocallRemote switch is in remote mode, the
motor can be operated from DCS with interlocks.
2. Both FD fan-I and I1 motor shall be operated to get 100% capacity.
3. Check back signals should be available for all the signals.
F D FAN-I1 (Drawing No. 8005-00-00-2-008)
AFBC is provided with 2 FD fans. Two FD fan motors are required to run the boiler at 100% MCR. Each
FD fan is provided with inlet control damper at its suction.

ON-SEQUENCE OPERATION:
Before starting the ON sequence operation of FD fan, the system shall ensure the following conditions

1) FD fan - I1 regulating vane should be at minimum position.

2) Close FD fan - I1 delivery damper.
Each FD fan is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequenck of that FD fan shall be initiated. The starting
impulse generated by the push button shall set the memory which shall reset automatically after the
starting sequence is completed.

ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the FD fan will set the start command provided the
following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.

a) FD fan-I1 bearing temperature at drive end not high.

b) FD fan-I1 bearing temperature at non-drive end not high.
c) FD fan-I1 suction damper at closed position.
d) FD f a n 4 delivery damper at closed position.
e) PA fan-I (or) PA fan-I1 runnmg.
f) Switch gear clearance O.K.
g) FD fan-I suction damper closed (or) FD fan-I motor running.
h) Furnace pressure normal.
Whenihe permissive conditions (a) to (h) are available, a white LED shall glow on the DCS, indicating
the av&lability of all the permissive conditions.
FD FAN-I1 ON:
The following actions shall be initiated after starting of FD Fan-11.
1. FD fan-I1 delivery damper shall open.
After the elapse of preset starting time (adjustable) and fulfillment of the above condition "ON" sequence
complete" condition is indicated by a white LED.
If the above condition is not satisfied and a preset starting time (adjustable), has elapsed, ON-sequence
fail condition is indicated by amber LED glow. "ON sequence complete" and "ON sequence fail"
conditions are recorded in the system. ON-sequence start memory will be reset automatically after a
preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions are indicated.
OFF SEQUENCE OPERATION:
Upon pressing this push button, the OFF sequence operation of the FD fan shall be initiated the impulse
generated by the push button shall set the OFF-sequence memory and trip the FD fan and also initiate the
following conditions.

a) FD fan-I1 delivery damper closed.

b) FD fan-I1 suction damper (regulating) closed.
c) PA fan-I motor not running.
d) PA fan-I1 motor not running.
If the above condition are satisfied and after elapse of preset stop time the "OFF-sequence complete"
condition is indicated by white LED glow or otherwise "OFF-sequence fail" condition will be indicated
by amber LED glow.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.

TRIPPING CONDITION:
a) The running FD fan shall trip under following condition
b) FD fan motor overload.
c) FD fan bearing temperature (DE) very high.
d) FD fan motor bearing temperature (NDE) very high.
e) Furnace pressure high.
i) The condition (a) will be connected directly to the MCC.
; ii) Local stop push button pressed is wired directly to MCC.

FD FAN-11:
Follo@g actions shall be initiated automatically.
i) suction and delivery damper of FD fan-I1 will be closed.

GENERAL NOTES:
1. When the LocalRemote switch in VFD panel is in local mode, the motor can be started either from
local or VFD panel without any interlocks. When the LocaVRemote switch is in remote mode, the
motor can be operated from DCS with interlocks.
2. Both FD fan-I and I1 motor shall be operated to get 100% capacity
3. Check back signals should be available for all the signals.
 F U E L FEEDER:(DrawngNo 8005-00-00-3-009)
ON-SEOUENCE OPERATION:
Before starbng the ON sequence operatlon of Fuel feeders the system shall ensure the followng
> cond~tions
1. Drag chain feeder running.

Each Fuel feeder is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that Fuel feeder shall be initiated. The
starting impulse generated by the push bunon shall set the memory which shall reset zutomatically after
the starting sequence is completed

ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the Fuel feeder start signal will be set provided the
following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.

1. Drag chain feeder running.

When the permissive conditions (1) is available, a white LED shall glow on the DCS, indicating the
availability of all the permissive conditions.

FUEL FEEDER ON:

The following actions shall be initiated after starting of Fuel feeder.
1. Vary the speed of VFD-1.
After the olapse of preset starting time (adjustable) and fulfillment of the above condition "ON" sequence
complete" condition is indicated by a white LED.
-,
If the above condition is not satisfied and a preset starting time (adjustable) has elapsed, ON-sequence
fail condition is indicated by amber LED glow. "ON sequence complete" and "ON sequence fail"
conditions are recorded in the system. ON-sequence start memory will be reset automatically after a
preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions are indicated.
 OFF SEQUENCE OPERATION:

Upon pressing this push button, the OFF sequence operation of the Fuel feeder shall be initiated. The
impulse generated by the push button shall set the OFF-sequence memory

a) Vary the VFD speed to zero

: If the above condition is satisfied and after elapse of preset stop time the "OFF-sequence complete"
1 condition is indicated by white LED glow or otherwise "OFF-sequence fail" condition will be indicated
1 by amber LED glow.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF
>
sequence fail" conditions are indicated.

TRIPPING CONDITION:
The runrnng Fuel feeder shall trlp under following condhon
I 1) Drag cham feeder not runnlng
..

FUEL FEEDER
i
Following actions shall be initiated automatically.
1 f) Speed variation of VFD

< GENERAL NOTES:

1. When the LocalRemote switch in VFD panel is in local mode, the motor can be, started either from
local or VFD panel without any interlocks. When the LocalIRemote switch is in remote mode, the
motor can be operated from DCS with interlocks

i 2. All Fuel feeders shall be operated to get 100% capacity

I

1
3. Check feed back signals should be available for all the signals
 AND MUST NOT BE COPIED OR LENT WlTHOUT THEIR PERMISSION IN WRITING.
FUEL AUTO
'
FEEDER SECECTOR TRIP
SWllCH IN ViO
REMOTE
1 RERER NOTE-3
----------
F l DRAG CHAIN FEEDER-@
0-60 SEC
NOTES :
01. OFF PUSH BUTDN OF VFD PND LOCAL ARE WIRED DIRECTLY TO THE VFD.
02. - - - C I R C U I T INCLUDED IN SWGR.
03. (#)MOTER CAN BE STARTED FROM MCC/LDCAL WITHDUT ANY INTERLOCK FOR TESTING PURPOSE D
1.SW.GR - SWIICH GEAR
A3
 , i .
2
THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYOS STEEL INDUSTRIES L I M E D .
AND MUST NOT BE COPlED OR LENT WrHOUT THEIR PERMISSION IN WRITING.
IF IN DOUBT. PLEASE ASK.
DO NOT SCALE THE DRG.
FUEL FEEDER-@ DRG CHAIN FEEDER-@
,, COMPARTMENT NO
MOTOR TAG NO FEEDER NO MOTOR TAG NO
1 M1
1 7 M7 DCF 1 GM 05 1
15 M13
I 2 M2
8 M8 DCF 2 GM 04 2
14 M14
DCF 3
DCF 4
5 M5
5 11 M11 5
17 MI7
6 M6
6 12 MI2 DCF 6 GM 08 6
18 MI8
DRAG CHAIN FEEDER: (Drawing No. 8005-00-00-3-010)
ON-SEQUENCE OPERATION:
Before starting the ON sequence operation' of Drag chain feeders the system shall ensure the following
conditions.

1. ED fan running.
2. Open FD air line damper.

Each Drag chain feeder is provided with ON-sequence start and OFF-sequence start push bunon. When
ON-sequence start push button is pressed, the starting sequence of that Drag chain feeder shall be
initiated. The starting impulse generated by the push button shall set the memoly which shall reset
automatically after the starting sequence is completed.

ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the Drag chain feeder start signal will be set provided
the following permissive conditions are available. The status of each permissive condition is indicated by
means of white LED glow.

a) FD fan-I (or) ED fan-I1 running.

b) Open ED air line damper of particular compartment.
c) Switch gear clearance O.K.
When the permissive conditions (a) to (c) are available; a white LED shall glow on the DCS, indicating
the availability of all the permissive conditions.

DRAG CHAIN FEEDER ON:

The following actions shall be initiated after starting of Drag chain feeder

ON-sequence fail condition is indicated by amber LED glow. "ON sequence complete" and "ON
sequence fail" conditions are recorded in the system. ON-sequence start memory will be reset
automatically after a preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions
are indicated.

OFF SEQUENCE OPERATION:

Upon pressing this push button, the OFF sequence operation of the Drag chain feeder shall be initiated.
The impulse generated by the push button shall set the OFF-sequence memory.

"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.
 TRIPPING CONDITION:
The running Drag chain feeder shall trip under following condition.
a) Drag chain feeder motor overload.
b) Closing of FD air line damper.

I c) FD fan motor not running

-I GENERAL NOTES:

i 1) When the Local / Remote switch in MCC panel is in local mode, the motor can be started either from

I
local or MCC panel without any interlocks. When the LocaliRemote switch is in remote mode, the motor

.> can be operated from DCS with interlocks.

2) Check back signals should be available for all the signals

3) Check back signals should be available for all the signals.

 CDMP-I CLOSED
01. OFF PUSH WTIDN OF MCC AND LOCAL ARE WIRED DIRECTLY TO THE MCC.
02. ------CIRCUIT INCLUDED IN SWGR.
03. (')MDTER CAN BE STARTED FROM MCC/LDC/IL WITHOUT AN INTERLOCK FOR TES~ING PURPOSE
 CLOSE OPEN GEARED
S.NO. DESCRIPTION REED SWITCH REED SWITCH S.NO. DESCRIPTION MOTOR
TAG NO. TAG NO. TAG NO.
1 FD AIR LINE DAMPER COMPARMENT-2 CLOSED ZSC-12DB 280-1204 D 4 C C M I N FEEDER-2 0-04
DRAG C M I N FEEDER-] 0-05
2 FD AIR LINE DAMPER COMPARMENT-1 CLOSED ZSC-12D7 280-1205
DRAG C M I N FEEDER-4 GM-06
3 FD AIR LINE DAMPER COMPARMWI-4 CLOSED ZSC-12DB 280-1206
DRAG C M I N FEEDER-5 GM-07
4 FD AIR LINE OAMPER COMPARMENI-5 CLOSED ZSC-12D9 280-1207
DRAG C M I N FEEDER-6 GM-OB
5 FD AIR LINE DAMPER COMPARUENT-6 CLOSED ZSC-121D 280-1208
 !
GEAR OIL PUMP-I: (Drawing No. 8005-00-00-3-01 1)

Gear Oil pump-I is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that Gear oil pump-I shall be initiated. The

I
starting impulse generated by the push button shall set the memory which shall reset automatically after

1
the starting sequence is completed.

ON-SEOUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the Gear oil will set the start command provided. The
j
status of permissive condition is indicated by means of white LED glow.
)
i) Switch gear clearance O.K.

GEAR OIL PUMP - I ON:

ON-sequence fail condition is indicated by amber LED glow. "ON sequence complete" and "ON
sequence fail" conditions are recorded in the system. ON-sequence start memory will be reset
automatically after a preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions
are indicated.

OFF SEQUENCE OPERATION:

Upon pressing this push button, the OFF sequence operation of the Gear oil pump-l shall be initiated. The
impulse generated by the push button shall set the OFF-sequence memory.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.

TRIPPING CONDITION:
The running Gear oil pump-I shall trip under following condition
a) Gearoil pump-I motor overload.
i) The conditions (a) will be connected directly to the MCC.
ii) Local stop push button pressed is wired directly to MCC.

GENERAL NOTES:
1. When the Local/Remote switch in MCC is in local mode, the motor can be started either from local or
/
MCC without any interlocks. When the Local/Remote switch is in remote mode; the motor can be
1 operated from DCS with interlocks.
I 2. Check back signals should be available for all the signals
L,
I
 335 OZL-0
03UldW03
035 U O 335 09-0
soc r------
I
- I
T
1Wj 035 NO I
I (IOPI-A)~~V~S
335 021-0 I I-dWnd 110 W33 lWlS
*I NOllfl8 HSnd
33N33n03S-JJO
-----------J
dm03 035 N0 I-dWnd 110 8V33
NOUnE HSnd
335 5 C-310N 83838
:,;
V 8 335 01-0 33W NI H311MS
dl81 80133335
omv M ...
' 3 8 0 3HL !1V3S LON 0 0 I 'LINIII8M NI NOISSlWL13d 813HI lnOHllM IN31 8 0 a31d03 38 ION 1SnW aNV
0311Wll 53lL1ISMNI 13315 Sa.4011 3 H I A0 Nbl3d08d 3 H I SI N31S3a aNV LINIMVUa SlHl
HSV 3 S m 7 d L 8 n 0 0 NI I,
.. -. . -.
9
-.
'
~

s
~.
-.
,~
.- -
P
> . ,
.- -.
--
~%
-
,
E Z
. . .
 GEAR OIL PUMP-11: (Drawing No. 8005-00-00-3-012)
Gear Oil pump-I1 is provided with ON-sequence start and' OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that Gear oil pump-I1 shall be initiated.
The starting impulse generated by the push button shall set the memory which shall reset automatically
I
after the starting sequence is completed.
I
ON-SEQUENCE START PUSH BUTTON PRESSED:
When "ON-sequence start" push button is pressed, the Gear oil will set the start command provided. The
status of permissive condition is indicated by means of white LED glow.
'I
i) Switch gear clearance O.K.
\

GEAR OIL PUMP - I1 ON:

ON-sequence fail condition is indicated by amber LED glow. "ON sequence complete" and "ON
sequence fail" conditions are recorded in the system. ON-sequence start memory will be reset
. .
i automatically after a preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions
.' ) are indicated.
j
OFF SEQUENCE OPERATION:
1 Upon pressing this push button, the OFF sequence operation of the Gear oil pump-I1 shall be initiated.

1 The impulse generated by the push button shall set the OFF-sequence memory.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
J

memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
I
1
sequence fail" conditions are indicated.

TRIPPING CONDITION:
1

The running Gear oil pump-I1 shall trip under following condition.
.-
\

a) Gear'oil pump-I1 motor overload.

1
~7

i) The conditions (a) will be connected directly to the MCC.

ii) Local stop push button is wired directly to the MCC.
,i
GENERAL NOTES:
i
1. When the LocaliRemote switch in MCC is in local mode, the motor can be started either from local
: J or MCC without any interlocks. When the Local/Remote switch is in remote mode, the motor can be
operated ftom DCS with interlocks.

, 2. Check back signals should be available Tor all the signals.

HP DOSING PUMP-I: (Drawing No. 8005-00-00-3-013)
HP dosing pump-I is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that HP dosing pump-I shall be initiated.
The starting impulse generated by the push button shall set the memory which shall reset automatically
after the starting sequence is completed.

ON-SEOUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the HP dosing will set the start command provided.
The status of permissive condition is indicated by means of white LED glow.
f) Switch gear clearance O.K.

HP DOSING PUMP - I ON:

ON-sequence fail condition is indicated by amber LED glow. "ON sequence complete" and "ON
sequence fail" conditions are recorded in the system. ON-sequence start memory will be reset
automatically after a preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions
are indicated

OFF SEQUENCE OPERATION:

Upon pressing this push button, the OFF sequence operation of the HP dosing pump-I shall be initiated.
The impulse generated by the push button shall set the OFF-sequence memory.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.

TRIPPING CONDITION:

The running
-\
HP dosing pump shall trip under following condition.
a) HP .dosing pump motor overload.
i) The conditions (a) will be connected directly to the MCC.
ii) Local stop push button pressed is wired directly to MCC.

GENERAL NOTES:
1. When the LocalIRemote switch in MCC is in local mode, the motor can be started either from local
or MCC without any interlocks. When the LocalIRemote switch is in remote mode, the motor can be
operated from DCS with interlocks.
2. Check back signals should be available for all the signals.
 THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYDS STEEL INDUSTRIES LIHrTED IF IN DOUBT , PLEASE ASK.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION I N WRmING. DO NOT SCALE THE DRG.
.I
REFER NOTE 4
ON-SEQUENCE
5 SEC
STLRT PUMP-I 1 \ ,
R
. . I ON s E o c o u p
5ART I ON
;----------- STOP I OFF
I
OFFFSEOUENCE
PUSH BUTlON d
START HP DOSING /cr
PUMP-I START 0-120 SEC
(M-01) I ON SEO FAIL
I
1
I
30s
(M-01)
I
--_------------A 0-60 SEC
OFF SEO
COMPLClED
D-12D SEC
OFF SEO FAlL
D
1. SW.GR- SWIEH GEAR
HP DOSING PUMP-11: (Drawing No. 8005-00-00-3-014)
HP dosing pump-I1 is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that HP dosing pump-I1 shall be initiated.
The starting impulse generated by the push button shall set the memory which shall reset automatically
after the starting sequence is completed.

ON-SEOUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the HP dosing will set the start command provided.
The status of permissive condition is indicated by means of white LED glow.
a) Switch gear clearance O.K.

HP DOSING PUMP-I1 ON:

ON-sequence fail condition is indicated by amber LED glow. "ON sequence complete" and "ON
sequence fail" conditions are recorded in the system. ON-sequence start memory will be reset
automatically after a preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions
are indicated.

OFF SEOUENCE OPERATION:

Upon pressing this push button, the OFF sequence operation of the HP dosing pump-I1 shall be initiated.
The impulse generated by the push button shall set the OFF-sequence memory.
"OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start
memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.

TRIPPING CONDITION:
The running HP dosing pump shall trip under following condition.
.-
\

a) HP dosing pump motor overload.

i) The conditions (a) will be connected directly to the MCC.
ii) Local stop push button pressed is wired directly to MCC.

GENERAL NOTES:
1. When the LocalIRemote switch in MCC is in local mode, the motor can be started either from local or
MCC wthout any interlocks. When the Local/Remote switch is in remote mode, the motor can be
operated from DCS with interlocks.
2. Check back signals should be available for all the signals
 -- -. - -- ,- .-
L - i -.~. .-> . -, ,'- .--- j- - .- .- - ,
-
__I
1 2 4 I 6
THIS DRAWING AND DESIGN IS THE PROPERTI OF THE LLOYDS STEEL INDUSTRIES LIMITED.
AND MUST NOT BE COPiED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
IF IN DOUBT .
PLEASE ASK.
DO NOT SCALE THE DUG.
SWITCH IN MCC
. .
REMOTE ,, AUTO TRIP
I I I i
OFF SEO FiUL
0-60 5EC
1. ALL S0PC.S ARE DOUBLE COIL/PUUE W P L
2. 0FF.PUSH BUTTON OF MCC AND LOCAL ARE WIRE0 DIRECTLY TO THE MCC.
3. ------ ClRCUll INCLUOEO IN SWGR.
4. (') MOTOR CAN BE STRATEO FROM MCC/LOCAL WITHOUT ANY INTERLOCK FOR TESilNG PURPOSE.
1. SW.GR- SWITCH GElR
I M E R L D C K LOGIC FOR H P DOSING P U M P MOTOR - I1
 IIP DOSING AGITATOR: (Drawing No. 8005-00-00-3-015)
HP dosing agitator is provided with ON-sequence start and OFF-sequence start push button. When ON-
sequence start push button is pressed, the starting sequence of that HP dosing agitator shall be initiated.

1 The starting impulse generated by the push button shall set the memory which shall reset automatically
after the starting sequence is completed.
3
', ON-SEQUENCE START PUSH BUTTON PRESSED:

When "ON-sequence start" push button is pressed, the HP dosing will set the start command provided.
The status of permissive condition is indicated by means of white LED glow.

-~ a) Switch gear clearance O.K.

HP DOSING AGITATOR ON:

ON-sequence fail condition is indicated by amber LED glow. "ON sequence complete" and "ON
sequence fail" conditions are recorded in the system. ON-sequence start memory will be reset
automatically after a preset time delay, after the ON-sequence complete 'or' ON-sequence fail conditions
1 are indicated.

OFF SEQUENCE OPERATION:

1
Upon pressing this push button, the OFF sequence operation of the HP dosing agitator shall be initiated.
The impulse generated by the push button shall set the OFF-sequence memory.
1 "OFF-sequence complete" and "OFF-sequence fail" are recorded in the system. The "OFF-sequence start

j memory will be reset automatically after a preset time delay after the "OFF-sequence complete" or "OFF-
sequence fail" conditions are indicated.
' I

TRIPPING CONDITION:.
, , The running HP dosing agitator shall trip under following condition.
.-
\

a) HP &sing agitator motor overload.

i The conditions (a) will be connected directly to the MCC.
i)
,1
.
ii) Local stop push button pressed is wired directly to MCC.
\
GENERAL NOTES:
.,,
1. When the LocalIRemote switch in MCC is in local mode, the motor can be started either from
.. ,
local or MCC without any interlocks. When the LocaliRemote switch is. In remote mode, the
. 1
~
motor can be operated from DCS with interlocks.

I 2. Check back signals should be available for all the signals

ON-OFF POWER CYLINDER OPERATED DAMPERS
PA FAN -I & I1 DELIVERY DAMPER (Drawing No. 8005-00-00-3-016)

The respective PA fan deliverydamper can be opened from DCS when the respective motor is running.
Closing of PA fan delivery dampers can be done through DCS without any interlocks.

FD FAN -I & I1 DELIVERY DAMPER (Drawing No. 8005-00-00-3-017)

FD fan-I & I1 delivery dampers has no interlocks and can be opened1 closed from DCS only.

PA AIR LINE DAMPERS FOR COMPARTMENT -1 TO 6 (Drawing No. 8005-00-00-3-018)

PA air line dampers has no interlocks and can be opened 1 closed from DCS only.

FD AIR LINE DAMPERS FOR COMPARTMENT -1 TO 6 (Drawing No. 8005-00-00-3-019)

The FD air line dampers of the respective compartment can be opened from DCS. when the PA a r line
damper of the respect~vecompartment is opened. Closing of FD air line dampers can be done through
DCS without any interlocks

ID FAN - I & I1 DELIVERY DAMPERS (Drawing No. 8005-00-00-3-020)

ID fan-I & I1 delivery dampers has no interlocks and can be opened I closed from DCS only.

AIR BLEED OFF VALVE

AIR BLEED OFF VALVE COMPARTMENT-I
( ~ r a w l no
n ~ 8005-00-00-3-021)
On closing of compartment-1 F D air line damper, compartment-1 air bleed off valve opens.
Similarly on opening of compartment-1 F D air line damper, the air bleed off valve close.
Similar arrangement for other compartment -2 to 6 with their respective compartment F D air line
damper opedclose signals.
,. . -. - -. -~
- .- .- -. --
&C,-
-L_..* 1-; , , _ j L.: , . .
-L2 .
-
, i ~J-.~;- -,-.; ', .+-.:- ,.-) -.,.
1 2 3 4 5 6
THIS DRAWING AND DESIGN IS THE P R O P E R N OF THE LLOYDS STEEL INDUSTRIES LIMITED. IF IN DOUBT , PLEASE ASK.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. DO NOT SCALE THE DRG.
PA FAN-I & I1 DELIVERY DAMPER
.
FROM ,',
,
DCS TO
I I
FIELD ' INTERLOCKS
1 INPUT
r
?"TEYBOARD SOFTWARE LOGIC
-I"-'
1
: INDICATION ' SOLENOID COIL BOX
I I I I I
OPEN LIMIT SWITCH
ACNATEO
A
I
I I ! A I OPEN
(RED)
'
I I I I I
CLOSE LIMIT SWITCH
ACNATED
I I I M CLEE
(GREEN)
1
:
I I I I I
PA FAN-I I I
I MOTOR RUNNING I I
I I
I
I I
-I ENERGIZE
OPEN SOLENOID COIL
I I I
I ENERGIZE
4
CLOSE SOLENOID COlL
I
i 1 L 1. . - . . - . . - . I
CLOSE
1. OCCURANCE OF EVENl IS CONSIDERED A5 LOGIC '1' IN ABOVE LOGIC
TAG NO. TAG NO.
2. OPEN/CLOSE PUSH BUTON PRESSEO IS CONSIDERED AS LOGIC "1'
3. SOLENOID COlL ARE PULSE N P E
-
..
-
--! -~
-. - .
1

-.
.
~-
- .-
2

.- .- - -
3
. ,
4 5'
.- , , ,
6
-. .,1-
THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYDS =EEL INDUSTRIES LIMITED. IF IN DOUBT PLEASE ASK.
AND MUST NOT BE COPIED OR LENT WlTHOUT THEIR PERMISSION IN WRITING. DO NOT SCALE
THE DRG.
FD FAN-I & 11 DELIVERY DAMPER
I_..-..-..-.._.._.._,
. .
FROM ,', DCS TO
I I
FIELD I INTERLOCKS ?~EYBOARD
r SOFTWARE LOGIC
7 -
: INDICATION :I SOLENOID COIL BOX
I ..-.. 1..INPUT
.- . . - ..L
-. - -.. - - ..-!, ,- . -.I - . -
I I I I
1
I ! OPEN
(RED)
I I I I
CLOSE LIMP SWITCH 1
?
I I I CLOSE
ACTUATED (GREEN)
I I I I
ENERGIZE
CLOSE SOLENOID COlL
I I
CLOSE
1. OCCURANCE OF M N T IS CONSIDERED AS LOGIC '1' IN ABOVE LOGIC REED SWIICH REED SWIICH
TAG NO. TAG NO.
2. OPEN/CLOSE PUSH BLmON PRESSED IS CONSIDERED AS LOGIC "1"
1 FD FAN-I DELIVERI DAMPER ZSO-1ZDI ZSC-1203
3 , SOLENOID COlL ARE PULSE M P E 2 FD FAN-I1 DELNERY DAMPER ZSO-12D2 ZSC-1204
 PA AIR LINE COMP. -1, 2, 3, 4, 5 & 6 DAMPERS
........................................................................ I-,.-..-.._..-..-.._
.,
' FROM I
,, DCS I
TO
FIELD ' INTERLOCKS !
1
'

KEYBOARD
INPUT
! SOFTWARE LOGIC
I
: INDICATION '
I
. SOLENOID COIL BOX
I I I I
OPEN LIMIT SWITCH I I OPEN
ACTUATED (RED) 1
I I I I
CLOSE LlMn SWITCH
ACTUATED
I I I M CLOSE
(GREEN)
1
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SOLENOID COlL ARE
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1 L 1
NOTES :
1. OCCURANCE OF N E W IS GONSIOERED PS LOGIG '1' IN MOVE LOGIC
2. OPENjCLOSE PUSH BUlTON PRESSED IS CONSIDERED PS LOGIC '1'
3. SOLENOID COlL APE PULSE TYPE
 OPEN REED CLOSE REED
S.NO DESCRIPTION SWITCH SWITCH
TAG NO. TAG NO.
1 PA AIR LINE OPYPER COMPARMENT-1 250-1213 25C-1220
2 PA AIR LINE OPYPER COMPARMENT-2 250-1214 25C-1221
3 PA AIR LINE OPYPER COMPARMENT-3 250-1215 25C-1222
4 PA AIR LINE OPYPER COMPARMENT-4 250-1216 ZSC-1223
5 PA AIR LINE OPYPER COMPARMENT-5 250-1217 2SC-1224
6 PA AIR LINE OPYPER COMPARMENT-6 250-1216 2SC-1225
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1 MISDRAWING AND OESICN IS THE PROPERTY OF THE LLOYD5 STEEL INDUSTRIES LIMITED. IF IN DOUBT , PLEASE ASK.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION I N WRIIING. DO NOT SCALE THE DRG.
FD AIR LlNE COMP. -1,2,3,4,5&6 DAMPERS
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FROM ,', DCS TO
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FIELD ' IN1.ERLOCKS
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SOFTWARE LOGIC
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: INDICATION ' SOLENOID COIL BOX
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I I I I I
ENERGIZE
I I I ' OPEN SOLENOID COlL
I I I I I
I ' m I 1 . i , ENERGIZE
CLOSE SOLENOID COIL
I I I I I
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1. OCCUWNCE OF M N T IS CONSIDERED AS LOGIC -1"
2. OPEN/CLOSE PUSH B m O N PRESSED IS CONSIDERED AS LOGIC 'I'
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IF IN DOUBT .PLE4SE ASK.
DO NOT SCALE THE DRG.
1 S.NO.1 DESCRIPTION
OPEN
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TAG NO.
CLOSE
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PA NR LlNE OMPER COMPARMEM-I
m AIR LINE MMPER COMPARMENT-2 PA AIR LlNE DAMPER COMPARMENT-2
3 m RAI UNE OMPER COMPMIMEHJ PA IUR LlNE DAMPER COMVMIUENT-3
4 FD AIR UNE DAMPER COMPeRMENT-4 4 PA NR LINE DAMPER COMPIRMENT-4
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2. OPEN/CLOSE PUSH BUTTON PRESSED IS CONSIDERED I LOGIC ''1' DESCRIPTION REED SWITCH REED SWITCH
TAG NO. TAG NO
3. SOLENOID COlL ARE PULSE WPE
I ID FAN-I DELlMRY DAMPER 280-1209 ZSC-1214
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AND MUST NOT BE COPIED OR L E W WmHDUT THEIR PERMISSIDN IN WRITING.
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IF I N D O U B T PLEASE ASK.
D O N O T SCALE THE DRG.
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AIR BLEED OF VALVE- 1
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SOFTWARE LOGIC INDICATION
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: AIR BLEED OFF VALVE
I I INPUT I I I
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AIR BLEED OFF VWLVE-1
OPEN LIMN SWITCH 1 1 I OPEN 1
KTUATEO
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- ENERGIZE
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NOTES :
-
-
I. OCCURANCE OF EVENT IS CONSIDERED AS LOGIC '1' IN ABOVE LOGIC EXCEPT INIERLOCKS.
SPECIAL NOTE%
D LLOYDS
-
ABWE IOGlC IS SIMILAR FOR AIR BLEED OFF VALVE-2.3,4,5&6.
WITH RESPECT TO FD AIR LlNE COMPARTMENT DAMPERS-2,3.4,5&6.
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DATE ISSUE RMSIDN All. CHD. I P D . CAPPD Iblrooauazl
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 OPEN CLOSE
S.NO DESCRIPTION LIMIT SWITCH S.NO1 DESCRIPTION LIMIT SWITCH
TAG NO. TAG NO.
1 AIR BLEED OFF VAVLE AT COMPARTMENT -1 250-1219 FD IUR LlNE DAMPER COMPARTMENT -I
2 AIR BLEED OFF VAVLE AT COMPARTMENT -2 250-1220 FD IUR LINE OAMPER COMPARTMENT - 2
3 AIR B L E D OFF VAVLE AT COMPARTMENT -3 250-1221 FO IUR LINE DAMPER COMPARTMEKi - 3
4 AIR BLEED OFF VAVLE AT COMPARTMENT -4 250-1222 FO IUR LlNE DAMPER COMPARTMENT -4
5 AIR BLEED OFF VAVLE AT COMPARTMENT -5 250-1223 m IUR LINE DAMPER COMPARTMENT -5
6 AIR BLEED OFF VAVLE AT COMPARTMENT -6 250-1224 FO IUR LINE DAMPER COMPARTMENT -6
 . . -. . .-..FRoY r..-..-..-..-..-..-"-,,
SOFIWARE LOGIC
I
 ,, OPEN CLOSE OPEN CLOSE
S.NO DESCRIPTION LIMIT SWITCH LIMIT SWITCH TORQUE SWITCHTORQUE SWITCH
TAG NO. TAG NO. TAG NO. TAG NO.
1 MDTORISEC VALVE FOR FCY ISOMTION AT UP STREAM (30%) 250-1101 ZSC-1101 TSO-11Dl l3-1101
2 MOTDRISEO V L V E FOR FCY ISOMTION AT UP STREAM (100%) ZSO-1102 ZSC-llD2 TSO-1102 EC-1102
3 MOTORISEO BYPASS V A L E FOR FEE0 CONTROL V L E (100%) 250-1103 ZSC-1103 TSO-1 l D 3 EC-1103
4 MDTORISEO VLVES FOR TCY l 9 U T l O N AT UPSTREAM ZSO-1105 ZSC-llD5 ED-llD5 TSC-1105
5 MOTORISEO VLVES FOR S P M Y WATER BYPASS LINE ZSO-1107 ZSC-1107 ED-1107 TSC-1107
6 MOTORISEO MAIN STEAM STOP VALVE ZSO-1109 ZSC-1109 ED-1109 TSC-1109
7 MOTORISEO V L E FOR INTERMITlENT BLOW DOWN ZSO-1302 ZSC-1302 ED-1302 EC-1302
 I c I d I 7 I < I
THiS DRAWING A N 0 DESIGN IS THE P R O P E m OF ?HE UOYDS STEEL NDUSTRILS LIMITED. IF IN DOUBT PLEASE ASK.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. DO NOT S C A L ~THE DRG.
FROM
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SOFIWARE LOGIC MCC
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CLOSE CONTACTOR
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: SWITCH ACTUATED : I I
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1. OCCURANCE OF EVENT IS CONSIDEREO AS LOGIC'!'.
2. OPEN/CLOSE PUSH BUT~ON PRESSED IS CONSIDEREO 6 LOGIC.!'.
3. SIMIUR ARRANGEMENT FOR MOTORISED STARTUP SIEAM VENT REGUVITING VALE.MOTORISE0 VALVE FOR CONTINUOUS BLOW DOWN,
MOTORISEO VALE FOR SPRAY WATER BYPASS LlNE N O MOTORISED VALVE FOR FEE0 CONTROL W P K S LlNE (IDOX).
D
- AMRM ANNUNC14TION
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THIS DRAWlNG AND OESICN 1s THE PROPERM OF THE LLOIDS STEEL INDUSTRIES LIMITED. IF IN DOUBT PLFASE ASK.
AN0 MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. DO NOT SCALE THE DRG.
...
A
OPEN CLOSE OPEN CLOSE
S.NO. DESCRIPTION LIMIT SWITCH LIMIT SWITCH TORQUE SWITCH TORQUE SWITCH
TAG NO. TAG NO. TAG NO. TAG NO.
1 MOTORISED EiPbSS VALVE FOR FEED CONTROL VALVE (100%) ZSO-1104 ZSC-1104 TSO-1104 1st-11D4
2 MOTORISEO VALE FOR SPRAY WATER BYPASS LINE 250-1106 ZSC-1106 TSO-1106 1st-llD6
3 MOTORISEO STARTUP STEAM K N T REGULAllNC VALVE ZSO-1108 ZSC-1100 TSO-1108 TSC-1lD8
4 MOTORISEO V A L E FOR CONTINUOUS BLOW DOWN VALE ZSO-1301 ZSC-13DI TSO-1301 TSC-13Dl
DP STUDY
DP study must be carried out individually for all compartments. In simple terms; DP study is nothing but
finding out thepressure drop across the Sporger Headers at different air flows. Follow the steps given
below.

DP study shall be done separately for each compartment. Hence close the FD, PA dampers of the
compartments which are not being studied.

Switch on ID fan, PA fan and then FD fan. Open the suction damper of FD fan and set 10 mm air flow in
Aerofoil meter. Measure the Compartment FD Header pressure and gas plenum pressure (ID fan damper
is to be adjusted to maintain a gas plenum pressure of -5 &wc at all conditions).
Suppose,
ED air flow = 10 mmwc across Aerofoil meter
Compartment ED Header pressure = 80 mmwc

Gas plenum pressure = -5 mmwc

The pressure drop across DP at 10 mm airflow =80 + 5 mmwc
= 85 mmwc

Thus, the pressure drop across DP can be found out 20, 30; 40, 50, 75 & 100 of air flow.
* The pressure drop values should be found out for other compartment too.

* The pressure drop values shall be compared. For the same air flow, if there is a deviation of more

than 5 mm between compartments, then it becomes necessary to check the following.

; * The manometer readings may be incorrect. Check for leakage in the pressure tapping locations or

Aero foil meter and Compartment FD Header.

.-
\

* Check for leakage in the impulse lines to manometer1 Draft indicator.

$ Check for leakage between fuel feed pipe and air box.

* Check for broken air nozzles.

* The pressure drop values found in DP study, shall be recorded for future use. The pressure drop
values measured in DP study are used to find out the bed height when the boiler is in running
condition i.e. at a particular air flow. Also it is used to establish the practical pressure drop across the
aero foil meter at the MCR air flow. If the DP drop is subtracted from the total drop across the bed
and DP. then bed height can be arrived.

$ The pressure drop values taken shall be recorded on the following tables for future reference.
 BED HEIGHT MEASUREMENT
DP STUDY CONDN OPERATING BED
P ~ - P I = BED HE^
DP STUDY READINGS

COMPARTMENT - 3

GAS PLENU SPORGER HEADER

(COMPARTMENT HEADER

COMPARTMENT - 4

GAS PLENUM SPORGER HEADER

(COMPARTMENT HEADER
 BED MATERIAL, CHARCOAL
KEROSENE & OIL REQUIREMENT
 \
BED MATERIAL, CHARCOAL. KEROSENE & OIL RElQUIRElMENT

BED MATERIAL REQUIREMENT:

Quantity of Bed material for initial startup : 151800 Kgs.

~~1
Quantity of Bed material for further 10 Startups : 152000 Kgs.
I
Total quantity bed material to be stocked : 303800 Kgs.

BEDMATERIAL SPECIFICATION:
Maximum particle size : 2.36 inm
Particles to pass through sieve No. :8
Minimum particle size : 0.85 mm
Particles to stay on sieve No. : 20
Particle density : 2000 ~ ~ / m ~
Bulk density : 1000 to 1100

Chemical composition
Alumina : 45% to 35%
Silica : 55% to 65%
Fusion temperature : 1400°C (Min.)
(Bed material shall be from Crushed refractory bricks or from sieved ash)

CHARCOAL REQUIREMENT:

Quantity of charcoal per startup : 300Kgs.

Quantity of charcoal to be stocked : 3000Kgs. (For 10 Startups)
,-\

CHARCOAL SPECIFICATION:

Charcoal size : 15 to 25 mm LUMPS

Calorific value : 6600 KcaliKg.

(Charcoal should be sundried)

KEROSENE:
Quantity of kerosene per startup : 33Litres.
Quantity of kerosene to be stocked : 330Litres. (For 10 Startups)

Quantity of Oil per startup : 40 Lkes/lu.

Quantity of Oil to be stocked : 400Litres.(For10 Startups)

L.,
, 130

I
.-,

I I
~ COMPARTMENTAL FLUIDISATION
USE OF BED MATERIAL

The bed material plays a vital role in the fluidised bed combustion process. The bed material is inert and
does not undergo any chemical change. The size of the bed material is so selected to meet the fluidisation
requirements. The bed material once heated serves like an ignitor for the incoming fuel. The normal bed
height when defluidised is maintained in the range of 300 mm to 400 mm. The bed material also acts as-
the carrier of heat between the burnt and the heat transfer surface.

PROCUREMENT OF BED MATERIAL

The bed material shall be procured from refractory supplier. Alternatively, the bed material can be
purchased from the user of a coal fired fluidised bed boiler. The ash drained from the fluidised bed can
be screened and used as bed material.

IMPORTANCE OF BED MATERIAL OUALITY AND QUANTITY

1. Before programming for a light up, it is necessary that the recommended quantity of bed material is
procured according to the specifications. The bed material is to be Stocked atleast for 10 start ups.

2. If the bed material is procured from a refractory supplier, ensure only refractory bricks are crushed to
make bed material. Mis up of insulation bricks is not allowed.

3. The fusion temperature of the bed material has to be above. If the fusion temperature is lower,
clinkering will occur in the bed.

4. It is important that the bed material is procured according to the size recommended. Oversize
particles do not fluidised well and fine powder will fly away. Also the fine powder puts off charcoal
fire while start up, (Because fine bed material quickly transfer heat to the bed coils).

5. In a"coal fired boiler, the ash produced from coal partly accumulates in the bed and the same is
drained to maintain a constant recommended bed height in the fluidised bed. This ash drained from
the bed can also be screened and the screened ash can be used as bed material.

6. A coal fired fluidised bed in operation contain good amount of fmes and coarse particles. Which are
due to varying coal particle size on crushing. Hence for every light up (except hot restart) fresh bed
material is to be used. This is essential for a smooth and quick start up.

7. When the bed material is procured from a refractory supplier, the size of the bed material is to be
specified up mentioning the upper sieve no. 8 and lower sieve no. 20. The material has to pass
through sieve no. 8 and to stay on sieve no. 20.
USES AND IMPORTANCE OF CHARCOAL:

1. Charcoal is required for lighting up of the boiler. A fixed quantity of charcoal is bumt in the fluidised
bed to raise the bed temperature in the start up compartment. Once the bed temperature is raised
further fuel is fed to establish combustion of fuel in the fluidised bed.

2. Charcoal is selected as the start up fuel, mainly, because of its high heat content, rapid burning
characteristics and low ignition temperature.

3. Good quality charcoal is a must for easy light up. Ensure charcoal is dry and not already bumt.
Heavier charcoal is an indication of good quality. ~ k a r i n dwood charcoal is the best because it
bums for more time and the calorific value is about 6600 kcallkg.

4. Charcoal should be dry for rapid burning. Wet charcoal should not be used in any case. Ensure the
charcoal in stock is also dry.

5. The charcoal should not contain powder or bigger lumps. The charcoal shall be sized to 15 - 25 mm.
Fine charcoal bums easily and does not contribute much for heating the bed. Bigger lumps would
cause clinker formation as the lumps do not easily fluidise.

BED MATERIAL FILLING:

The bed material can be filled by entering the furnace. For start up purpose, the bed height shall be
200 - 225 mm above the air nozzle top level in the start up compartment.

The bed material below the nozzle level remains static all the time. This is not to be counted as the
bedheight.
Uniform spreading can be done by admitting flu~disingair through the bed. The air should be
sufficient enough to fluidise bed.

The bed height can be measured physically after putting off the air flow

Alternatively the bed height can be found out by pressure drop across the fluidised bed

Let us assume,
For 100 mm fluid~singair flow the Sporger Header pressure drop across the air nozzle is found to be 150
mm.

Let gas plenum pressure = 10 mmwc

Let compartment pressure drop across the fluidised bed = 325 mmwc
132
The pressure drop across the fluidised bed and the
bed and the air nozzle = 335 mmwc

The pressure drop across the air nozzle is 150 mmwc as found in DP study.

The pressure drop across the bed = 335 - 150.

= 185 mmwc

Since the bulk density of the bed material is 1000 kg/m3, the pressure drop across the bed in mm is the
bed height in mm.

Though the normal operating bed height is 300 - 400 mm, initial bed material filling is done only upto
200-225 mm. This low bed height reduces the charcoal requirement for start up purpose. Also low bed
height helps in raising the boiler pressure slowly.

In the case of compartmental start up the bed material shall be filled as explained below:

Fill the bed material to a height of 300 mm in all compartments. Fluidise all the compartments together
provided the fan motor dampers are below the limits. If not possible, fluidise two compartments together
for leveling. Then the next compartment can be fluidised separately. The start up compartment is to be
fluidised separately. When this is done a portion of the bed material spills to the adjacent compartment
and forms a mount along the edge of the compartment. Further bed material is to be added to the start up
compartment so that the bed height of 200 - 225 mm is maintained.
BOILEK LIGHT-UP

The lighting up of the boiler is to be done with the help of charcoal and kerosene. The light up is to be
done only for 4 single compartment. After stabilizing with a single compartment fire is transferred to
other compartments as per the procedure explained separately.

PREPARATIONS:
1. Inspect the boiler prior to starting and check the following.
- All access doors are closed.
- All personnel cleared.
- All foreign materials are removed from furnace and pressure parts
- Starting equipment aid interlocks are in position.
- Boiler is filled with DM water above the low level limit.

2. Check the following equipments for adequate lubrication and readiness for service.

- Fans and drives.

- Feed pumps and drives.
- Fuel feeders and controllers.
3. Check dry fuel (0-6) mrn is available in the bunker, the gates below, the bunker are open and fuel is
available at feeder inlet.

4. Check the instrument air is available at the required pressure (of 7 kglcm2) for instrumentation and
control.

5. Check the following valves in the Boiler drum are closed.

- Feed control valve and its bypass valve.
:- Blow down valve.
- Main steam stop valve.
- Drain valves of water level gauge.
6. Check the following valves are kept open.
- Air vent on top of drum.
- Water level gauge, pressure gauge and level transmitter I isolation valves
- Valves before and after the feed control valve in the feed line.
- Valves on the feed line connecting to the feed pumps in operation.
7. Check the bed material is filled in the furnace and fluidisation study is complete.
BOILER FILLING:
Before starting the filling up, keep the vent on the drum open and close the blow down and drain valves.
The filling up is done by running the feed pumps hut the rate of flow is controlled by means of feed
control valve. During the filling up check the operation of blow down valve and drain valves and then
close them. The boiler is filled up completely till water comes through the drum vent and is drained to
bring the water level to low level alarm limit.

FLUIDISATION STUDY:
* During the fluidisation studies, except for large compartments the fuel transport air need not he
introduced as it would disturb the bed.

* Observe the fluidisation of the start up compartment by varying the air flow gradually. Mark the
position of dampers when the bed matenal begins to fluidise. In the case of pneumatically operated
dampers, note the input signal "psi" from the manual loaders.

" The on set fluidisation may also be observed by plotting the bed pressure drop against the air flow.

* Set the air flow at 5 mm P.

* Measure the compartment air header pressure, PI mm wc
*
Add the gas plenum pressure P2 to P1 (Pl+[P2]) is the pressure drop across the air nozzle and bed.
* Substact P3 mmwc, which is the pressure drop across DP alone which is measured in DP study, i.e.,
(PI + [P2]) - P3 would be the pressure drop across the tied

* ' The pressure drop across the bed is thus obtained for various air flows. The readings may he plotted
in a graph as shown.
* Theair flow at which fluidisation starts is noted. This value is to be maintained for the purpose of
mixing at the time of startup.
* Once the fluidisation study is completed, the fans shall be switched off and boiler shall he taken for
light up.
 The boiler light up is done using charcoal and kerosene as explained below

" A fixed quantity of dry charcoal is spread uniformly over the start up compartment,

I " A fixed quantity of Kerosene mixed charcoal is spread uniformly over the dry charcoal layer
1
The fire is initiated using swab.

Further by proper air flow control, fire can be spread and the heat released by charcoal is utilised to
heat the bed material to a temperature above the ignition temperature of the fuel.

i * In the process of preheating bed material the required fluidisation velocity is maintained in the bed
by suitably opening the FD fan inlet damper.

Further the fuel feed rate is adjusted to maintain a bed temperature of 800°C to 850°C.

The charcoal of size below 15 mm shall not be accounted for the above

>
Keep the ID fan damper open at the time of lighting up. This would reduce the possiblllty of furnaces
J
, puff.

1 * Initiate the fire bushing number of swabs. Throw the swabs in such a way that the fire spreads
1 uniformly over the entire furnace. If the spreading of the fire is non uniform sprinkle some kerosene
choked charcoal and throw it to the locations where fire is not there. Unless the fire is more or less
. j
present over the entire surface, it is advised not to proceed with the light up. Unless the top layer or
: charcoal gets ignited, further charcoal would not get ignited.
 BED TEMPERATURE AND AIR FLOW CONTROL

The thermocouples are located in such a way that they are well utilised for start up.

The top level bed thermocouple is located at a height to read the temperature just at the buming charcoal
layer. The bottom level thermocouple is located to read the bed material temperature at a height of 100
mm from nozzle level.

After the introduction of fire, top level thermocouple temperature will go up. It is very important to
increase the air flow gradually in order to increase the top level temperature to 800°C. At first the ID fan
damper opening alone allows some leakage air. Further opening of FD fan damper will add some more
air to increase the bed temperature. Now close ID fan and FD fan inlet dampers. Start ID fan then FD fan.
Open ID fan and FD fan inlet dampers step by step to increase the top level temperature to 800°C to
850°C.

Till this period the bottom level thermocouple would not have shown increase in temperature. Once the
top level temperature reaches 800 - 850°C, the burning top layer of charcoal shall be mixed with rest of
the bed. The mixing is done by increasing the air flow so as to fluidise the bed. The mixing air flow
should not be higher than that of the air flow established during the fluidisation study. For this purpose
the markings made on damper positions shall be used.

If the mixing is done at higher airflow, the buming charcoal will spill into the adjacent compartment.
More than the loss of charcoal in the start up compartment, the bed height will reduce in start up
compartment. This would lead to defluidisation as the air would tend to bypass at bed heights lower than
100 mm.

The duration of mixing shall be between 20 - 30 seconds. During the mixing process, the I top level
temperature would start reducing. At the same time, bottom level temperature would begin to rise.

Soon after the mixing is completed the air flow is brought to a minimum. Open the man hole door and
visuall<.ensure thorough mixing has been done. If top layer charcoal has not been disturbed at some
places, mixing shall be carried out once again.

After ensuring thorough mixing, the air flow shall be brought down to minimum and then shall be
increased in steps. The airflow shall be increased gradually so as to raise the bed temperature. The
airflow shall be brought up at MCR airflow in process of raising bed temperature above 600°C.

Once the bed temperature shoots above 60OoC, the fuel transport lines are to be dechoked and fuel flow
shall be established.

*
Switch on the PA fan
I

Open the fuel transport air dampers of the start up compartment

 Check the suction at the mixing nozzle. If suction is not available, open the respective bottom drain
gates of fuel pipes to dechoke, if any. After the choking of fuel feed pipe is cleared close the gates.
" In the case of larger compartments it is advisable to initiate minimum airflow in fuel pipe lines just
before mixing process to avoid choking of the fuel lines.
" Adjust the PA fan. suction damper, to maintain the header pressure in between 700 to 900 mmwc
" Initiate the fuel flow by switching on the fuel feeders. The fuel flow shall be kept minimum at the
beginning. At the time of fuel feed initiation, the charcoal might not have burnt fully. Hence it is
most important to initiate fuel feed gradually.
* Excess fuel feed will increase the bed temperature uncontrollably. Though the bed temperature can be
controlled by increasing the air flow, it is advisable to take care at the time of fuel feed initiation.
Stabilise the start up Compartment operation with a bed temperature of 850°C and with the MCR air
flow.

* On the waterside watch the drum level. If the level goes down switch on feed pump and regulate the
feed control valve. ONIOFF operation of feed pump should be avoided to the extent possible. If the
feed pump is auto operated, keep the selector switch in auto mode. Here again regulate the feed
control valve to avoid frequent startlstop of the pump.
* Close the drum vents at 2 kg1cm.' pressure if the boiler is provided with superheater. This is done so
that superheater coils are cooled better by more steam flow through them. Ensure the vents, start up
vents, drains are open in superheater lines. The condensate in superheater coils and main steam pipe
should have been removed earlier. In the case of non drainable sections of superheater coils it is
possible that condensate leads to water hammer.
" In cases of powercut during start up after the mixing it will not be possible to access how much
charcoal is burnt out. It is advised to cool thoroughly and drain the bed material in start up
compartment and do a fresh light up.
* However, if the powercut had occurred before mixing one may attempt to light up as below:
* Sprinkle Kerosene soaked charcoal through man hole evenly over the start up compartment. The
I
charcoal quantity shall be the same as that for light up.
-j
* Throw swabs and light up.
* Follow the same procedure as discussed in a regular light up.
* If the powercut occurs after mixing and provided the duration is also short, it may be possible to light
1 UP.
* Fluidise the bed minimally. Check the bed temperature. If the bed temperature is more than 400°C
add dry charcoal to the bed. The charcoal should be thrown uniformly over the entire bed. Observe
the rise in temperature, if there is no improvement in bed temperature it is better to cool the bed.
Never allow the bed to be static in this method. If the bed is static, clinker formation will start.
COMPARTMENTAL TRANSFER:
The start up with one compartment is recommended for the following reasons.
1. Gradual loading of pressure parts.
2. Reduction of Charcoal for start up
3. Load variation.

The compartment transfer means activating a static (cold) compartment of the furnace adjacent to the
activated compartment. This is done just by admitting the fluidising air to the compartment to be
activated and mixing the cold material with hot material of the operating compartment.
Before activating a static compartment, the airflow in the fluidising compartment shall be increased to
120% of the MCR air flow, and the fuel feed rate shall be correspondingly increased to maintain the bed
temperature at 900°C.
Now open the compartment air damper of the adjacent compartment which is to be activated. The cold
bed material in this compartment would begin to mix up with that of hot bed material in the operating
compartment. The bed temperature in new compartment would begin to rise.
The bed temperature in operating compartment will begin to drop. Once this temperature reaches 750°C
slump the new compartment by closing the air damper.
The bed temperature of the operating compartment shall be once gain brought up to 900°C before
another attempt is made.
By following the process of mixing the bed material of the compartment to be activated with that of the
operating compartment, on one or many attempts, the activation can be completed. The bed temperature
of the new compartment shall be brought to atleast 600°C before fuel feeding is commenced.
The primary air lines in the new compartment shall be opened and the fuel feeding can be commenced
and the bed temperature shall be brought to 800°C with MCR fluidising air flow condition. Care shall be
,-\

taken not to drop the temperature of operating compartment below 600°C in the process of activating
adjacent compartment.
If by mistake, the temperature of the operating compartment drops below 600°C, it becomes necessav to
raise the temperature using charcoal. The charcoal should be sprayed over the entire compartment.
Charcoal should be mixed with the bed keeping the bed minimally fluidised. The charcoal if bums under
static condition, the chance of clinkering is high.
 NORMAL OPERATION
LOAD CONTROL:

The steam generation needs to be matched with that of demand to avoid venting of steam. If the steam
drawn fromthe boiler is less compared to steam generated then the pressure would rise and thus resulting
in lifting of safety valve. Frequent lifting of safety valve will damage the safety valve seat. Steam
generation can be varied by slumping compartments or by varying the fluidisation air flow or by varying
the bed temperature or by varying the bed height.

Load variation of 70% to 100% may be obtained by varying the bed temperature. The bed temperature
can be reduced upto 700°C and can be increased to 900°C based on demand. For this purpose the fuel fed
rate needs to be varied. Further turndown is also possible by reducing the fluidisation airflow but not to
the extent of defluidisation of the bed. In such cases the air flow through primary air lines should never
be reduced. Only the fluidising airflow should be reduced. Further load control is done by slumping the
compartments. The compartments can be slumped only from either ends of the bed. In case of two
compartments any compartment may be slumped.

Slumping of the compartment is to be done as explained here. Bring down the fuel rate to minimum and
switch off the feeder. Wait till the bottom bed temperature comes around 850°C, and then close the
fluidising air damper of the compartment. Then close the fuel transport air line dampers. When the
fluidising air through a compartment is cut off, the air through the other compartments would increase.
This air flow shall be adjusted by throttling inlet damper of FD fan. Further draft in the funace shall be
adjusted by throttling of ID fan inlet damper.

Reactivation of a compartment shall be done in the following sequence. Open the fuel transport airline
valves first and ensure the required air pressure is available in the PA fan header. If the line is choked,
choke shall be removed by using the drain gates, of the fuel transport lines. Then open the fluidising air
I damper-and set the FD fan inlet damper for the required MCR airflow. If the bed temperature is above

.i 600°C. fuel feed shall be initiated and the bed temperature shall be brought to the required operating
temperature.
->
".)
In case the temperature of the bed is less than 600°C immediately after fluidisation, the compartment
shall be started in the manner explained in the compartment transfer method. The load control is
.A
graphically depicted in figure for the furnace with four compartments
..I During one compartment operation, the bed height can not be increased as the bed is not contained on
>
.J one side. This is applicable to some extent to two compartments operation also maximum variation is
possible in all compartments operation as the bed is totally contained in all four sides by the furnace
water wall
.I
DYNAMICS IN FLUIDISED BED:

The height of the fluidised bed needs to be increased after the activation of all compartments in order to
meet the steam demand. In the case of coal firing, the bed height automatically increases due to
generation of ash from coal burning. The ash which is retained in the bed, if not drained, will accumulate
to an extend that the airflow through the bed starts coming down below the MCR airflow. The height of
bed is not to be allowed to increase beyond the recommended bed height which is about 300 mm to 400
mm. The bed height is indirectly measured by means of Compartment Header pressure as explained in
the earlier sections. Other than the purpose of maintaining required bed height, the bed hopper drain
gates are to be operated for removing higher size particles. When there are deviations from the specified
fuel feed size, i.e., minus G mm, the higher size particles would begin to settle down at the air nozzle
level.

The bed drain is to be operated frequently to drain the higher size particles. If the drain is not operated
frequently the fluidisation will be upset causing clinker formation.

ASH REMOVAL:

The ash should be drained from all collection points. Failure to remove the ash will result in choking of
flue gas path.

BOILER TRIPPING DUE TO POWER CUT:

In case of boiler tripping due to power cut or for any other reason, immediately close the inlet dampers of
the FD fan and ID fan. In the event of power availability and if the boiler is required to be started
immediately switch on the fans. Establish the MCR air flow and start fuel feeding. Otherwise if the boiler
is to b e boxed up, close the main steam stop valve. Close the compartment dampers also. The boiler can
be restarted as explained in the further chapters. (Write up on hot restart).

INGRESS OF FOREIGN MATTER IN FUEL:

Ingress of cotton waste: waste cloth, coconut shell, mango seed etc., will block the fuel flow from the
chute into the feeder. This is indicated by the drop in bed temperature (provided the feed rate of the
feeder is not increased).

The above mentioned problems can be eliminated if a screen is provided in the fuel handling system.
Feeder tripping due to foreign material is a great nuisance and at times it may lead to boiler shut down. In
case of coal, it becomes n e c e s s q to provide a magnetic separator to separate out the tramp iron from the
coal. This not only protects the crusher: but also prevents to damage to the feeder.
 At times it may so happen that the foreign matter may block the fuel transport line. When there is no
airflow in the fuel transport line, the bed material from the bed enters the fuel feed nozzle and leads to
\, choking of the line. The choking shouid be removed by slumping the bed and by opening the drain gates.
Also the foreign matter should be removed from the mixing nozzle opening the plug of the mixing
)
nozzle.
/ NORMAL SHUT DOWN TO COLD

4
1 Reduce the fuel feed rate and stop the fuel feeders. Maintain the same air flow to cool bed faster. If the
steam is not drawn from the boiler, open the airvent to reduce pressure. If it is not necessary to enter the
1I 1 boiler for maintenance, slow rate of pressure and temperature decay is desirable switch off the fans after

1 I the bed has cooled down to 500°C. Switching off the fans should be in the order of FD, PA and ID fans.
If it is desirable to accelerate the cooling process in order to permit entry into the unit for maintenance,
the fans could be continued to run at the same flow rate until temperature reaches 100°C. During the
process maintain normal water level in the boiler. After the bed temperature reached 100°C open the
blowdown valve and drain the boiler. (The boiler water temperature must be reduced atleast 90°C before
draining). Drain the bed material. This can be done by opening the gates below the compartment
Hoppers, collect this bed material, sieve and reuse for subsequent light ups.
CONTROL LOOPS

THREE ELEMENT DRUM LEVEL CONTROL

FURNACE DRAUGHT CONTROL

SUPERHEATED STEAM TEMPERATURE CONTROL

COMBUSTION CONTROL

AIR HEATER BYPASS DAMPER CONTROL

BED ASH REMOVAL

THREE ELEMENT DRUM LEVEL CONTROL
(This document should be read in conjunction with Drawing No. 8005-00-00-3-024)

PURPOSE:
To maintain constant level in the steam drum by controlling the feed water flow.

MEASURED VARIABLES:

a. Drum level is measured by three level transmitters (LT1301, LT1302 & LT1303).Triple redundancy
is considered for level measurement.

b. Steam flow is measured by one steam flow transmitter (FT1102) across the flow nozzle.

c. Feed flow is measured by one flow transmitter (FT1101) across the flow element.

d. Steam line pressure is measured by a pressure transmitter (PTI 101).

e. Steam temperature is measured using the thermocouple (TEI 108).

f. Drum pressure is measured by one drum pressure transmitter (PT1301).

CONTROL PHILOSOPHY:

For normal operation median signal from three level transmitters are used as control input signals. In case
of failure of any one of thee level signals the other two inputs are averaged and taken for control. Here 2
out of 3 logics is followed for drum level control. The median of the thee level transmitter received by
level controller is processed in a PI controller and an output is generated.

a) Drum level signal is density compensated using the drum pressure signal. Steam flow signal is
compensated by steam pressure and temperature signal.

b) T6e.compensated steam flow signal is then routed to a summator block.

c) The second signal to the summator block is the output of level controller from step (a)

d) The output of the summator block is given differential block controller

e) The output from distributor module is connected to differential block where the set point is to be set
by the operator. If there is excessive difference between the measured value and set point the loop
shall trip AutoiManual station to manual.

f) The output of the differential block is given as cascade set point to feed water flow
g) The output from the differential block is fed to the PI controller.

h) The output from step (g) is connected to the control valves as described below.
 The three element control regulates the water supply to the boiler drum through feed water control
valves. Upto 30% of boiler load drum level is controlled by low load feed control valve using single
element. Above 30% of boiler load the control is by full load control valve using three element control.

T1 - Low load to full load transfer switch.

T2 - Auto manual selector switch for low load to full load transfer.

02. When T2 is in Auto Mode

i) Steam flow is less than 30% FI(X) will work in input-output mode (ie., output =input) and F2(X)
output will be zero.

ii) When steam flow increases to 30% Fl(X) output will reduce to zero following a ramp and
simultaneously F2(X) output will increase from zero, following an inverse ramp upto 30% of boiler
load. The ramp is adjustable. Any change in full load controller output from 30% shall be
superimposed on the F2(X) output to maintain level.

iii) When steam flow reduces to 30% F2(X) output will start reducing to zero following ramp and
simultaneously Fl(X) output will start increasing following an inverse ramp. The ramp is adjustable.
Any change in low load controller output from 30% will be superimposed on Fl(X) output.

iv) During auto transfer period if T2 is transferred to "Manual" mode, Both 30% and100% controllers
will be transferred to manual and output of the controllers shall be equal to final control outputs
(Going to final drive) and Fl(X) as well as F2(X)will be transferred to input-output follow mode

03. When T2 is in Manual mode,

>: "
i) TL-is transferred to low load control position, FI(X) and F2(X) will be in input-output follow mode.
%.

I Full load controller will be transferred to manual with zero out put and output of low load controller
will be transferred to Auto mode with same effect as the last value of full load controller output.
-')
)
ii) T1 is transferred to full load control position, Fl(X) and F2(X) will be in input-output follow mode,
low load controller will be transferred to manual mode with zero output and full load controller will
_, be transferred to Auto mode with same effect as the value of low load controller output.
iii) During auto transfer from low load to full load and vice-versa "ZT" signal will be utilized to check up
response to open close command and in case the valve does not respond within pre-determined period
alarm will be available and controllers will trip to manual. Same shall be alarmed as "Unsuccessful!
Auto Transfer" During Auto transfer, massage "Auto transfer in process" shall be available in CRT.

f ) Position feed back of feed control valve is taken to DCS and displayed in CRT.

g) The output from LIC and FIC respectively for single element and 3 element drum
Level controls go through individual H/A selector block.
 -
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FURNACE DRAUGHT CONTROL
(This document should be read in conjunction with Drawing No. 8005-00-00-2-025)

PURPOSE:
To maintain the furnace pressure constant at the desired value for all boiler loads. This is achieved by
throttling the suction dampers of ID fan-I & 11.

MEASURED VARIABLES:
a). Furnace pressure is measured using a pressure transmitter (PT1209)

CONTROL PHILOSOPHY:

a) The fumace pressure signal is fed to the distributor module.

b) The output from distributor module is connected to differential block where the set point is to be set
by the operator. If there is excessive difference between the measured value and set point the loop
shall trip AutoIManual station to manual.

C) The output from the differential block is fed to the PI controller.

d) The controller performs PI action on the input signal.

e ) The output signal from step (c) is connected to WA block.

f) The output of WA is connected to distributor module

g) The distributor module is connected to WA block of

,, i) Both 1D fan electrical Actuator-I and electrical Actuator-I1 if VFD is out of Operation bypass
starting envisaged. The mode can be selected as auto (or) hand accordingly. The output is
connected after ensuring that the corresponding ID fan is in operation.

h fan I & I1 motors vide their VFD's if VFD is in operation.

i i j ~ o t 1D

The WA block output is connected through Bias block to 1IP convertor

h) When fumace pressure increases the ID fan electrical Actuator opens and when furnace pressure
decreases the electrical Actuator closes and thus maintains the furnace pressure as a constant value.

i) Position feed back of electrical Actuator is taken to DCS and displayed in CRT
 . '
I I
THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYDS STEEL INDUSTRIES LIMITED. IFIN DOUBT PLEASE ASK.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. DO NOT SCALE THE DRG.

FROM (SH 1 OF 3)
I

h
ID FUI-I
MOTOR MOTOR
(UO5)
(UOI)

ELECTRICAL ACTUATOR FOR ELECTRICAL I\CTUATOR FOR

ln FMI-I l k n ~ lF ~ I ~ OOaUPFR
M ID FAN-I1 (6DX) SLlllON DAMPER
 -
" - : :
-. -
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~~

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-
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. .,
- - -.
, .
*-:.>-
\.-.l,l_L
-
-.-.-.-. 7
.- -.-
-L..L., .-i~
~.
.: _--,.i .-
1 2 3 4 5 6
THIS OFAWING AND DESIGN IS THE PROPERTY OF THE LLOYDS STEEL INDUSTRIES LIMITED.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
.
IF I N D O U B T ?LEASE ASK.
D O N O T S C A L E T H E DRG.
NOTES:
1. ALL TRANSMInERS SHALL BE POWERED FROM DCS.

INTERLOCK: I /

TRlP CONTROL TO MANUAL ON @ ON ID FAN-I TRlP THE ELECTRICAL ACTUATOR SHOULD COME TO ITS MINIMUM POSITION.

@ RELEASE ID FAN-I AND ID FAN-I1 INLEI DAMPER TO MANUAL MODE, WHEN COMBUSTION COTROL a ON ID FAN-I1 TRlP THE ELECTRICAL ACTUATOR SHOULD COME TO ITS MINIMUM POSITION
LOOP IS CHANGED TO MANUAL MODE. 6 THE LOOP SHALL FALL BACK TO MANUAL MODE AT THE FOLLOWING CASES.
@ RELEASE ID FAN- INLEl DAMPER TO MANUAL MODE, WHEN COMBUSTION COTROL LOOP IS CHANGED o) BAD VALUE FROM THE TRANSMIlTER.
MANUAL MODE. b) INCORRECT READING FROM THE POSITION TRANSMInER.
@ RELEASE 10 FAN-11 INLR DAMPER TO MANUAL MODE, WHEN COMBUSTION COTROl C) EXCESSIVE DEMATlON BEWEEN MEASURED VALUE OF S E I POINT.
LOOP IS CHANGED TO MANUAL MODE.

@ THIS BLOCK IS ACTUATED ONLY WHEN ID FAN-I MOTOR IS RUNNING.

@ THIS BLOCK IS ACTUATE0 ONLY WHEN ID FAN-I1 MOTOR IS RUNNING

ALARM LIST:
@ FURNACE PRESSURE HIGH ALARM.
@) FURNACE PRESSURE LOW ALARM.
 SUPERHEATED STEAM TEMPERATURE CONTROL:
(This document should be read in conjunction with Drawing No. 8005-00-00-3-026)

PURPOSE:
To mantan constant superheated steam temperature
>

-~ MEASURED VARIABLES:
a) Main steam line temperature is measured using a thermocouple (TE1108)
.\ b) The thermocouple output is connected to temperature transmitters (?TI 10 1)

~,
CONTROL PHILOSOPHY:

a) The main steam line temperature signal is fed to the distributor module

b) The output from distributor module is connected to differential block where the set point is to be set
by the operator. If there is excessive difference between the measured value and set point the loop
/
, , shall trip AutolManual station to manual.
.
C) The output from the differential block is fed to the PID controller.
.I
j
d) The controller performs PID action on the input signal.
1
i

, >,
e) The output signal from step (d) is connected to HIA block and the mode can be selected as auto (or)
hand accordingly.

, .-
\

T h e ' k block
~ output is connected to distributor module from which both the 100% & 100% bypass
1
spray control valves are controlled.
i
: :
f) Position feed back of spray control valve is taken to DCS and displayed in CRT.
..I

.J! g) When the superheater steam temperature increases, the superheater spray control valve opens and

,. J when the superheated steam temperature decreases, the desuperheater spray control valves closes and
thus maintains the temperahre.
. ,I
 N
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 THIS DRAWING PND DESIGN IS THE PRDPERN OF THE LLOYDS STEEL INDUSTRIES LIMITED.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
IF IN DOUBT .
PLEASE ASK.
DO NOT SCALE THE DRG.

FROM (SH 1 OF 3)

I
DlSTRlBUTOR
MODULE

Y11N SlUM LINE

TNPEPAlURE
CONTROL VILYE(1CV 1101)

H AFBC BOILER
NO 0, B o a I"0.
,OmWLPP SUPER HEATFX S T U N TEMPERATURE CONTROL
CmmNm:
M E I ISSUE I RMSION za~$ooov~o~ti DR*mc 8005-00-00-3-026
(SHEET 2 OF 3) ar NO: 00
I I 7 I < I c 15
 - - -. .- - - --
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. ,

2'
. --,L>JL
3 ---T
.-._-._i
~

4
_ -. -. .- L.
j-.
5
.-; .-.,' , ..-- .--
6
-

THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYDS STEEL INDUSTRIES LIMITED.
AND MUST NOT BL COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
I F I N DOUBT .P L E A S E ASK.
DO NOT S C A L E T H E DRG.

NOTES : ,,

1. POSlllON TRANSMllER SHALL BE POWERED FROM DCS

INTERLOCK :
TRIP CONTROAL TO MANUAL ON

@ THE LOOP SHALL BACK TO MANUAL MODE AT THE FOLLOWING

0) BAD VALUE FROM M E TRANSMInER.

b) INCORRECT READING FROM THE POSTION TRANSMlnER.

ALARMS LIST:
@ STEAM TEMPERATURE ALARM HIGH

a STEAM TEMPERATURE ALARM LOW

 1
COMBUSTION CONTROL

(This document should be read in conjunction with its Drawing No. 8005-00-00-3-027)
'\
The objective of the combustion control is to ensure that the air flow into the furnace is proportional to
> the total amount of fuel entering the fumace at any instant. Normally, air flow will be slightly more than

~) the theoretical air requirement for a given fuel.

, ,
Too much of air leads to high excess air and higher loss in efficiency. Too less an air leads to insufficient
combustion and also leads to clinker formation. Hence the combustion control is very important and it is
divided into two parts.

~1 1. Air flow control

2. Fuel flow control

AIR FLOW CONTROL:

In this control the air flow is varied corresponding to the variation in steam flow
)

1
GENERAL POINTS IN AIR FLOW CONTROL:
1
1. The combustion control should not be used during boiler startup

)
2. Combustion control should be put in Auto mode only after all the compartments are actuated atleast
once
1

3. For combustion control to be in auto mode atleast 3 compartment should be in operation

4. The air flow Vs steam flow curve is furnished. From this curve the minimum and maximum air flow
fGvarious compartment combinations can be obtained.
)

5. Whenever the air flow reaches the high and low limits, alarms should be generated.
~J
. ,\

. ~
MEASURED VARIABLES:
,.J
1. Air flow is sensed through air flow transmitter (FT1201) located across the aerofoil at air heater
I
~..
outlet.
J 2. Steam flow is sensed through steam flow transmitter (FT1102). The steam flow signal is suitably
\
./ compensated by steam pressure and temperature. (Ref. Drg. No. 8005-00-00-2-024 for steam flow
i measurement).
3. The number of compartments in operation is sensed in DCS using the signal from limit switches
CONTROL PHILOSOPHY:

a) The air flow signal is density compensated using the FD air pressure signal and FD air temperature
signal.

b) The output from the Compensation block is fed to the distributor module.

c) The output from distributor module is connected to differential block where the set point is to be set
by the operator. If there is excessive difference between the measured value and set point the loop
shall trip AutoIManual station to manual.

d) The output from the differential block is fed to the PI controller. The DCS
should perform the following

The no. of compartments in operation has to be checked with help of the digital inputs from the limit
switches. Based on the no. of compartments in operation there is a maximum limit (XH) and
minimum limit (XL) for the air flow. For example if all 6 compartmeflts are in operation the
maximum air flow is 121.526 TPH and the minimum air flow is 14.18 TPH (Considering fuel as
UKHNl coal). There are 6 sets of such limits namely XHl.XH2 XH3, XH4; XH5.XH6 &
XLl.XL2. XL3; XL4, XL5, XL6.

1. Corresponding to the steam flow there will be air flow value from the air flow Vs steam flow
curve. (Refer attached curves - 2 sheets). The air flow value will go as the set point to the air flow
controller.

, 2. If this set point is between the maximum and minimum limits for the particular number of
compartment in operation, then the controller output will go to
i) The respective final control element i.e., regulating power cylinders at FD fan suction damper
through an auto / manual selector block, if VFD is out of operation or if a particular fan is not in
operation, then the signal should not go to that electrical Actuator.

ii) To both the FD fan motors operated vide VFD if VFD is in operation

3. The air flow set point should go to the high limit (A Max) in case the bed temperature (defined
under fuel flow control) goes to 975°C.
ALL 6 COMPARTMENTS IN OPERATION:

a) Supposing the steam drawl is more, then the corresponding set point for air flow also will increase. If
the set point crosses the high limit (XH) then the DCS should generate an alarm "STEAM DRAWAL
IS MORE" and the air flow is brought to a freeze at the high limit.

b) Supposing the steam demand is less, then the corresponding set point for air flow also will decrease.
If the set point goes the low limit (XL), then the DCS should generate an alarm (STEAM DRAWAL
IS LESS-SHUT DOWN ANY ONE COMPARTMENT).

The following compartment cut off sequence should be done by DCS

i) A signal should trip fuel feeder of one compartment,

ii) Consequently the air line damper of that particular compartment has to be closed

LET US CONSIDER 5 COMPARTMENTS IN OPERATION:

a) When the air flow set point corresponding to the steam flow is between the maximum and minimum
air flow limits for 5 compartments in operation, then the air flow controller output will operate the
final control element, that is the electrical Actuator at the suction of the FD fans.

b) If the steam drawal increases and the corresponding air flow set point reaches the high limit, then
a l a m starting "STEAM DRAWAL IS INCREASED - ACTIVATE A NON OPERATING
COMPARTMENT" should be generated and the following compartment cut in sequence should be
done by DCS.
i) The FD air line damper of that compartment should be opened.
ii) Ensure that the PA air line damper of that compartment is open.
iii)'The fuel feeder of that compartment should be started after ensuring that the bed temperature of
that compartment is 2 600°C.

c) When the air flow set point reaches the low limit then the DCS should perform the compartment cut
off sequence as explained earlier.
I
FUEL FLOW CONTROL:
MEASURED VARIABLES:

a. The main steam line is measured using pressure transmitter (PT 1101).
b. The fuel feeder speed is sensed using the VFD1201 to VFD1212.
c. Bed temperature of all the compartments are sensed using the thermocouples (TE1202 to TE1225)
and then respective temperature transmitter (TT1202 to TT1225).

4 Nos. of thermocouple are provided in each compartment. The bed thermocouple signal is the main
criterion for boiler operation. Since we have 4 thermocouple signals, the average value should be
considered as the bed temperature.

For averaging, erratic signal should not be considered, erratic signal is one of the following.

i) Temperature signal of the operating compartment showing less than 600°C

ii) Open circuit in thermocouple.
iii) Temperature difference of more than 50°C.

Following are the various temperature zone, defined in the FBC boiler

a. NORMAL BED TEMPERATURE:

The average bed temperature in the range of 800°C to 950°C is defined as normal bed temperature

b. LOW BED TEMPERATURE:

The average bed temperature in the range of 700°C to 800°C is defined as the low bed temperature.

c. HIGH BED TEMPERATURE:

The average bed temperature in the range of 950°C to 975'C is defined as the high bed temperature,

d. VERY HIGH BED TEMPERATURE:

The average bed temperature above 975°C is defined as very high bed temperature. The DCS shall also
have some dead band (behveen 10°C to 20°C) between the two temperature zones. The dead band shall
be applicable for decreasing trend only. (i.e. from very high temperature zone to high temperature zone).
 CONTROL PHILOSOPHY:

In the fuel flow control, the speed of the fuel feeder i.e. the fuel feed rate, is controlled based on the
,
steam pressure and the bed temperature.
"7 The steam pressure signal goes to the steam pressure controller which is given a set point for steam
'. ~l pressure Based on the deviation this controller generates an output which is given as a cascade set point
to the fuel feeder controllers of the individual compartments. The fuel feeder controller output is
connected to the fuel feeder of the individual compartments through the output selector block.
. .
The function of the output selector block is as follows.

,I

i) NORMAL BED TEMPERATURE

When the bed temperature is normal, the DCS should give output based on the difference in steam
pressure signal (output mode A1 i.e., (F)) as explained above.
The output should go to all the running fuel feeders parallelly so as to decreases or increase the fuel
feeder speed.
. ,

. .I ii) 1i.e. ((F + A F) '

I,
When the bed temperature is low, the DCS should first bring the temperature to normal. This is achieved
, by incrementing the fuel feed speed (i.e. original fuel feeder speed + some incremental value). The DCS
shall have provision for time gap (in terms of minutes) between one increment and the next increment of
.;
fuel speed. The actual time will be decided after commissioning the boiler. The 4-20 mA output from
fuel feeder VFD will be taken into DCS and the same should be calibrated to VFD speed. Normally the
incremental value can be 10%to start with and provision shall be available in DCS to change the same in
future.,,Once the bed temperature comes to normal zone, the DCS should work based on the steam
pressure signal.
,.)

I , iii) HIGH BED TEMPERATURE (Output mode 'A3' ie (F - A F)

1 '.: When the bed temperature is high, the DCS should first bring the temperature to normal. This is achieved

1
,
>,
' 1
.,
by decrementing the fuel feed speed (i.e. original fuel feeder speed + some decremental value). The
. . decremental value can be 10%to start with and provision shall be available in DCS to change the same in
3 future.
5 ,
The DCS shall have provision for time gap (in terms of minutes) between one increment and the next
' ,

1 . : increment of Fuel speed. The actual time will be decided after commissioning the boiler. Once the bed
temperature comes to normal zone, the DCS should work based on the steam pressure signal
I
iv) VERY HIGH BED TEMPERATURE

The fuel feeder of that particular compartment should be tripped (&). Once the temperature comes to
below 800°C. The fuel feeder can be switched ON.

GENERAL POINTS ON FUEL FLOW CONTROL:

01. DCS shall have provision for the following.
a) The combustion control loop should be by passed during the boiler start-up

b) For combustion control to be in auto mode minimpm two compartments should be in operation.

c) The current output of the fuel feed controllers should be within the specified limits. The upper
limit of the current output is fixed by the maximum speed corresponding to the maximum carrying
capacity, moisture content and calorific value. The maximum speed of the fuel feeders will be about
10% more than the normal speed required at full load when all the compartments are in operation.
The upper and lower limits of the current output will be informed during cohnissioning and should
be possible to change the values at site based on the operating conditions.

2. Speed of fuel feeders shall be manually operated from VFD panel also

3. If the steam pressure is high and correspondingly the fuel feed rate is reduced then the bed
temperature will start falling. However if the temperature falls below 80O0C, even if the pressure is
high, fuel feeding is to be increased to maintained bed temperature of >80O0C and <900°C.
 X3018
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THlS DMWING AND DESIGN IS THE PROPERR OF THE LLOYDS STEEL INDUSTRIES LIMITED. IF I N D O U B T PLEASE ASK.
AND MUST NDT BE CDPED OR LENT wnnour THEIR PERMISSION IN WRITING. DO NOT SCALETHE DRG.

1. ALL TRANSMmERS SHALL BE POWERED FROM DCS.

INTERLOCK:
TRlP CONTROL TO MANUAL ON
a RELEASE FD FAN- M I D FD FAN-I1 INLCl DAMPER TO MANUAL MODE. WHEN FURNACE PRESSURE
COTROL LOOP IS CHANGED TO MANUAL MOOE.
@ AIR FLOW S F I POINT SHOULD GO TO HlGH LIMIT IN CASE THE BED TEMPERATURE GOES TO 975'C. I I
0 THE COMBUSTION CONTROL LOOP SHOULD NOT BE ACTIVATED DURING BOILER STARTUP.
@ RELEASE FD FAN-I INLEl DAMPER TO MANUAL MOOE, WHEN COMBUSTION COTROL LOOP IS CHANGED ONCE.
TO MANUAL MODE.
@ COMBUSTION CONTROL SHOULD BE P a IN AUTO MOOE ONLY AFlER ALL THE COMPARTMENTS ARE ACTIVATED ATLEAST
@ RELEASE FD FAN-I1 INLET DAMPER TO MANUAL MODE. WHEN FURNACE PRESSURE COTROL
LOOP IS CHANGED TO MANUAL MODE. @ FOR COMBUSTION CONlROL TO BE IN AUTO MODE ATLEAST 2 TO 6 COMPARTMENT SHOULD BE IN OPERATION.
@ THlS BLOCK IS ACTUATED ONLY WHEN FD FAN-I MOTOR IS RUNNING. WHEN AIR FLOW S E I POINT REACHES LOW LIMIT COMPARTMENT CUT-OFF SEQUENCE IS TO BE DONE

@ THIS BLOCK IS ACTUATED ONLY WHEN FD FAN-11 MOTOR IS RUNNING. o) A SIGNAL SHOULD TRlP FUEL FEEDER OF ONE COMPARTMENT.

b) CONSEQUENTLY THE AIR LINE DAMPER OF THAT PARTICUMR COMPARTMENT HAS TO BE CLOSED.
@ ON FO FAN-I TRlP THE REGULATING POWER CYLINDER SHOULL COME TO ITS MINIMUM POSITION.

a ON FO FAN-II TRIP THE REGULA~NG POWER CYUNOER SHOULD COME TO ns
@ THE LOOP SHALL FALL BACK TO MANUAL MODE AT THE FOLLOWING CASES,
a) BAD VALUE FROM THE TRANSMITrER.
b) INCORRECT READING FROM THE POSITION TRANSMmER.
MINIMUM POSITION. @ IF THE BED TEMPERATURE REACHES 9 7 % (REFER SH 4 OF 6). THEN THE AIR FLOW S F I POINT SHALL GO TO THE
MAYlMUM VALUE FOR THAT PARTICUMR SET OF COMPARTMENTS.
@ 'A' MODE WlLL BE SELECTED UNDER THE NORMAL OPERATING CONDITION 'A - M U ' MODE WlLL BE SELECTED IF
TEMPERATURE IS 'A4'.

ALARM LIST:
ALARM HlGH

@ AMRM LOW

LLOYDS STEEL INDUSTRlES LIMITED.

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THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYDS STEEL INDUSTRIES LIMITED.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
IF IN DOUBT. PLEASE ASK.
DO NOT SCALE THE DRG.
..
I

FUEL FLOW CONTROL

MAIN '
STEAM PRESSURE

lNDlWITlON
TO T H R E EKMENT IN DCS
DRUM L M L CONTROL TO OUTPUT SELECTOR BLOCK
(1No. PIC BLOCK COMMON TEMPERATURE (SH 5 OF 6)
(sons-oo-oo-2-024) HIGH k LOW
FOR ALL COMPARTMENTS)

TO SELECTOR BLKK
(SH 5 OF 6)
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IF IN DOUBT.
6
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PLEASE ASK.
THIS ORAWING AND O D l G N IS THE PROPERN OF THE LLOYDS STEEL INDUSTRIES LIMITED
, . AN0 MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. DO NOT SCALE THE DRG.

FROM (SH 4 OF 6)

t
(mlp)
FROM AUTO MANU& STATION Al. (F) A4'
(SH 4 OF 6)
U (F+bF) A3'(F-bF) (1 No. PER COMPARTUEKI.
THERFORE 6 N o n FOR BOILER)
 - -
THIS DRAWING AND DESIGN IS THE PROPERTY OF THE LLOYDS STEEL INDUSTRIES L I M E D . IF I N D O U B T , P L E A S E A S K .
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. D O N O T S C A L E T H E DRG.

I TRIP CONTROL TO MANUAL ON I II

@ OF THERMOCOUPLES SHOULC NOT BE CONSIDERED WHEN THERE IS ANY ERRACTIC SIGNAL. @) WHEN THE BED TEMPERATURE IS HIGH, THE DCS SHOULD FIRST BRING THE TEMPERATURE TO NORMAL.
ERRACTIC SIGNAL IS ONE OF THE FOLLOWING, . . THIS IS ACHIEVED BY DECREMENTING THE FUEL FEEDER SPEED (ie. ORIGINAL FUEL FEEDER SPEED - SOME
I 1 0) TEMPERATURE SIGNAL OF THE OPERATING COMPARTMENT S H O W I ~ GLESS THAN 600.C 1 DECREMENTAL VALUE). (OUTPUT MODE A3 ie. F-AF). THE DECREMENTAL VALUE CAN BE 107. TO START WITH AND 1 I
PROVISION SHALL B f AVAILABLE IN DCS TO C H A N G ~THE SAME IN FUTURE. THE DCS ASHALL HAVE PROVISION FOR THE
b) OPEN CIRCUIT IN THERMOCOUPLE.
GAP (IN TERMS OF MINUTES). ONE INCREMEW AND THE NEXT INCREMENT OF FUEL SPEED. THE ACTUAL TlME WILL BE
C) TEMPERATURE DIFFERENCE OF MORE THAN 5 0 C DECIDED DURING COMMISSIONING THE BOILER. ONCE THE BED TEMPERATURE COMES TO NORMAL ZONE, THE DCS SHOULC

H 1
WORK BASED ON THE STEM PRESSURE SIGNAL.
@ WHEN THE BED TEMPERATURE IS NORMAL, THE DCS SHOULD G I M OUTPUT BASED ON THE DIFFERENCE
IN STEAM PRESSURE SIGNAL (OUTPUT MODE 'Al' ie (F). THE OUTPUT SHOULD GO TO ALL THE RUNNING @ THE FUEL FEEDER OF WAT PARTICULAR COMPARTMENT SHOULD BE TRIPPED ( ~ 4 ) . WHEN THE BED TEMPERATURE GOES
FUEL FEEDERS PARALLELY SO AS TO DECEREASE OR INCREASE THE FEEDER SPEED. BEYOND 975'C. ONCE THE TEMPERATURE COMES TO BELOW 925'C. THE FUEL FEEDER CAN BE SWITCHED ON.
@ WHEN THE BED TEMPERATURE IS LOW, THE DCS SHOULD FIRST BRING THE TEMPERATURE TO NORMAL. @ THE COMBUSTION CONTROL LOOP SHOULD BE BY PASSED DURING THE BOILER START UP.
THIS IS ACHIEVED BY INCREMEWING THE FUEL FEED SPEED (ie. ORIGINAL FUEL FEEDER SPEED t SOME
INCREMENTAL VALUE). (OUTPUT MODE A2 ie. FtAF). THE DCS SHALL HAVE PROVISION FOR TlME GAP
@ COMBUST1ON COWROL BE IN 'ODE COMPARTMEMS SHDULD BE IN OPERATION

(IN TERMS OF MINUTES) BElWEEN ONE INCREMENT AND THE NEXT INCREMENT OF FUEL SPEED. THE
ACTUAL TlME WILL BE DECIDED DURING COMMISSIONING THE BOILER. THE 4-20 MA OUTPUT FROM FUEL
FEEDER VFD WILL BE TAKEN INTO DCS AND THE SAME SHOULD BE CALIBRATED TO M D SPEED.
NORMALLY THE INCREMENTAL VALUE CAN BE 1 0 Z TO START WmH AND PROYiSlON SHALL BE AVAILABLE
IN DCS TO CHANGE THE SAME IN FUTURE. ONCE THE BED TEMPERATURE COMES TO NORMAL ZONE, THE
DCS SHOULD WORK BASED ON THE STEM PRESSURE SIGNAL.

@ BED TEMPERATURE HIGH.

@ BED TEMPERATURE LOW.

-- L L O Y X STET: I V 2 L S T R I F S :.!YITFI)
'\..LLxh.":>.. e..:.:
I I AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. DO NOT SCALE THE DRG.
I

STEAM FLOW Vs AIR FLOW CURVE

FUEL:UKHNI COAL

STEAM FLOW (TPH)

CLWT LLOYDS METALS & ENGINE

GHUGUS,CHAP
m. SA 50310
WG- BY
M l s Urn Produ~reEnaneenne IP) Ltd.. TIRUCHIRAPALLI-620020 BOILW NO. : 111
 1 2 3
THIS DRAWING AND DESIGN IS THE PROPERlY OF THE LLOYDS STEEL INDUSTRIES LIMITED.
AND MUST NOT BE COPIED OR LENT WlTLiOUT THEIR PERMISSION IN WRITING. DO NOT SCALE THE DRG

X-AXIS 1 CM = I 0 mrnWc
Y-AXIS 1 CM = 1 0 0 0 0 kg/hr

h in rnrnWc-

AIRFOIL METER Q vs h

DRN.
.
SVK
NG 1 18120P
<8.12,09
c m - LLOYDS METALS
GHUGUS. ENGINEERS LTD.
& MAHARASHTRA
CHANDRAPUR, ERK REF.NO.:

ENGINEERED BY
s m 1:1

I
 1 2 3
THIS DRAWING AND DESIGN IS THE PROPERT OF THE LLOYDS STEEL INDUSTRIES LIMITED. IF I N DOUBT , PLEASE ASK.
AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING. DO NOT SCALE THE DRG.

1 SCALE
kg/hri
X-AXIS 1 CM = 10 mmWc
Y-AXIS 1 CM = 10000
w" MCR - 12144 x fi kg/hr
~
h=192 mm

h in rnmWc-

AIRFOIL METER Q vs h
A I R H E A T E R BYPASS DAMPER CONTROL:

(This document should be read in conjunction with Drawing No. 8005-00-00-3-028)

PURPOSE:
To maintain constant flue gas temperature (1 15°C) rn ESP inlet.

MEASURED VARIABLES:
ESP inlet flue gas temperature is measured using a thermocouple (TE1221)

CONTROL PHILOSOPHY:
a) The ESP inlet flue gas temperature signal is fed to the distributor module.

b) The output from distributor module is connected to differential block where the set point is to be set
by the operator. If there is excessive difference between the measured value and set point the loop
shall trip AutolManual station to manual.

C) The output from the differential block is fed to the PID controller.

d) The controller performs PID action on the input signal.

e) The output signal from step (d) is connected to H/A block and the mode can be selected as auto (or)
hand accordingly.
The HIA block output is connected to distributor module from which the airheater bypass damper is
controlled.

f) Position
.~ \
feed back of air heater bypass damper is taken to DCS and displayed in CRT

g) When the ESP inlet flue gas temperature decreases, the airheater bypass damper opens and when the
ESP inlet flue gas temperature increases, the airheater bypass damper closes and thus maintains the
temperature.
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THIS DRAWING AND DESIGN IS THE PROPERTI OF THE LLOYDS STEEL INDUSTRIES LIMITED.
AND MUST NOT BE COPIED OR LENT WITHOU~ THEIR PERMISSION IN WRITING^
. - -. -..-

IF IN DOUBT
6
.
"

PLViSE ASK.
DO NOT SCALE THE DRG.
- .- ,
'

ELECTRICPL ACTUATOR FOR ELECTRICAL ACTUATOR FOR

PA FAN-I (100%) SUCION DAMPER PA FM-11 (100%) SUCTION DAMPER

1. PDSITION TRANSMITER SHALL BE POWERED

BED ASH REMOVAL
(This document should be read in conjunction with Drawing No. 8005-00-00-3-032)
Each compartment hopper is provided with two nos of knife edge gate valve operated with power
cylinder. One gate is located at the bottom of the straight chute and other gate is located at the top of the
chute. (ie., at bottom of the hopper).

PURPOSE:
To maintain the Bed height by removing the Bed Ash

MEASURED VARIABLES:
The high ash level in the compartment is sensed by the compartment air header pressure transmitter
Each compartment is having Ash Hoppers. Any compartment's bed ash level can be controlled
independently with the help of solenoid operated power cylinder provided.

CONTROL PHILOSOPHY:

The ash level high signal from any of the compartment shall initiate alarm in the DCS. The gate opening
of the respective compartment for draining the ash by manual only.

MANUAL MODE

The operator by visualising the high alarm signal, the top gate to be closed first and then the bottom gate
to be opened for ash drain. After draining the ash, the bottom gate to be closed and top gate to be opened.
Again drain the ash by opening the bottom gate. This procedure shall be repeated till the bed height
maintains
.-\
in the furnace.

If ash level is maintained the sequence shall be stopped. Care should be taken such that the compartment
which is not running is not opened.
I HOPPER TOP GATE 1 HOPPER BOTTOM GATE

OPEN CLOSE 1
REED SWITCH REED SWITCH REED SWlTCd
TAG NO.
1 TAG NO. TAG NO. TAG NO.

ZSO-1226
ZSO-1227
ZSO-1228
290-1229
ZSO-1230